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OPTO 22 SNAP PAC Redundancy Option User Manual Download Page 4

SNAP PAC Redundancy Option User’s Guide

iv

Chapter 4: Creating a Strategy with Controller Redundancy   . . . . . . . . . . . . . . . . . . . .  31

Glossary of Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Persistent/Redundant Data   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Redundant Control Engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Sequential Programming  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Sync Block   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Transaction   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Transactional Chart  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Creating a Redundant Strategy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Step 1. Enabling the PAC Control Redundancy Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Step 2. Adding a Redundant Control Engine to a PAC Control Strategy   . . . . . . . . . . . . . . . . 36

Adding an Existing Redundant Control Engine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Configuring an Existing Control Engine for Redundancy  . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Step 3. Configuring Persistent/Redundant Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Persistent/Redundant Variables  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Configuring Redundant Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Step 4. Designing a Transactional Chart  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Transaction Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Design Considerations and Chart Constraints   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Using Reads and Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
What Causes Synchronization to Occur  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Adding a Sync Block  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Chapter 5: System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  47

Checking System Status  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Redundant System Status Messages  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Using the Memory Map to Read Status Messages  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Using the Memory Map to Enter and Exit Maintenance Mode . . . . . . . . . . . . . . . . . . . . . 50
Entering Maintenance Mode on Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Redundant System State Machine  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Changing an IP Address on a Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Installing New Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Installing Firmware to the Controllers  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Using the Running System Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Using the Controller Method  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Installing Firmware to the Arbiter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Managing Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Using Advanced Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Using Controller Redundancy – Debug Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Arbiter Status LEDs and Blink Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Communication Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
System Status LEDs  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Resetting the Arbiter  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Summary of Contents for SNAP PAC Redundancy Option

Page 1: ...044 Business Park Drive Temecula CA 92590 3614 Phone 800 321 OPTO 6786 or 951 695 3000 Fax 800 832 OPTO 6786 or 951 695 2712 www opto22 com Product Support Services 800 TEK OPTO 835 6786 or 951 695 30...

Page 2: ...ux and Pamux are registered trademarks of Opto 22 Generation 4 groov Server ioControl ioDisplay ioManager ioProject ioUtilities mistic Nvio Nvio net Web Portal OptoConnect OptoControl OptoDataLink Opt...

Page 3: ...nnecting the PAC S series Controllers 9 Connecting SNAP PAC S2 Controllers 10 Connecting SNAP PAC S1 Controllers 11 Wiring the 7 pin Serial Connector on SNAP PAC S2 Controllers 13 Wiring the 10 pin Se...

Page 4: ...tional Chart 41 Transaction Example 43 Design Considerations and Chart Constraints 43 Using Reads and Timers 44 What Causes Synchronization to Occur 45 Adding a Sync Block 45 Chapter 5 System Maintena...

Page 5: ...were to fail for whatever reason a second identically configured controller takes over with almost no down time The SNAP PAC Redundancy Option provides the tools for developing a control system with...

Page 6: ...ce on a PAC S or PAC R controller and a secondary IP address to the controller s other Ethernet interface If communication to the primary address fails the secondary address takes over There are two b...

Page 7: ...e PAC S series controllers connected to it via a dedicated RS 485 link If the arbiter detects improper operation of the primary controller the arbiter switches control to the secondary controller The...

Page 8: ...ower Switch The SNAP RPSW redundant power switch is a relay device designed especially for use in a SNAP PAC redundant system Connected to the SNAP PAC SRA arbiter and both controllers this switch res...

Page 9: ...ous other system maintenance tasks Related Documentation For more information on topics related to the SNAP PAC Redundancy Option see the following Opto 22 documents For this information See this guid...

Page 10: ...Support engineer PC configuration type of processor speed memory and operating system Software and version being used Controller firmware version A complete description of your hardware and operating...

Page 11: ...gher A crossover cable to connect the two controllers 10BASE T or 100BASE TX Ethernet network The SNAP PAC Redundancy Option Kit part number SNAP PAC ROK which includes a SNAP PAC SRA arbiter and a SN...

Page 12: ...he system will continue to run if any single component fails or in any situation where the currently active controller does not fail and can still communicate to I O If both the arbiter and the active...

Page 13: ...R1 CTR2 Serial 2 SNAP PAC S2 1 SNAP PAC S2 2 Serial 2 To network Crossover cable ENET 2 ENET 1 Ethernet connections Serial connections This section includes the following topics Connecting SNAP PAC S2...

Page 14: ...NET 1 connect the controllers to the network 3 Connect Serial 2 on Controller 1 to CTR1 on the arbiter using RS 485 2 wire mode 4 Connect Serial 2 on Controller 2 to CTR2 on the arbiter using RS 485 2...

Page 15: ...he 6 pin Serial Connector on the Arbiter on page 14 1 Using ENET 2 on both controllers connect the controllers to each other with a crossover cable To network Crossover cable ENET 2 ENET 1 2 Using ENE...

Page 16: ...re mode requires a single twisted pair for the data wires and an additional insulated wire for the signal common connection It is usually easiest to use a two pair shielded RS 485 data cable as follow...

Page 17: ...PAC S2 but the pin orientation is different Instead use the connectors supplied with the SNAP PAC S2 controller Legacy OptoControl Controllers G4LC32 G4LC32SX G4LC32ISA G4LC32ISA LT M4 M4IO M4RTU SNAP...

Page 18: ...driver insert or remove the wire as needed 3 Release the orange tab Hole Orange tab Connecting Power Using the Power Connection Diagram on page 15 connect power to the arbiter controllers and switch a...

Page 19: ...black white wire red white wire Power Connection Diagram CHAPTER 2 CONNECTING THE HARDWARE SNAP PAC Redundancy Option User s Guide 15 15...

Page 20: ...CONNECTING POWER SNAP PAC Redundancy Option User s Guide 16...

Page 21: ...ontrol network Assigning a Primary IP Address to ENET 1 on each Controller Each device must have a valid IP address and subnet mask so that it can communicate on the network If your controllers alread...

Page 22: ...TE BootPbroadcastscannotgetthroughafirewallinthePCwherePACManagerisrunning Makesure any firewall in the computer such as the built in firewall in Windows is disabled before you try to assign IP addres...

Page 23: ...ation Does the controller already have an IP address To change the IP address see Changing an IP Address on a Device on page 52 Is the controller booting to the loader rather than the firmware See the...

Page 24: ...CAUTION Each device on your network including computers routers controllers brains and so on musthaveauniqueIPaddress FailuretoassignuniqueIPaddressesmaycausecatastrophicnetwork or hardware failures...

Page 25: ...ckly blinking status light If the device is not currently in BootP mode see Resetting the Arbiter on page 62 to restore factory default settings NOTE BootPbroadcastscannotgetthroughafirewallinthePCwhe...

Page 26: ...list of units requesting IP addresses NOTE If no MAC address appears check the following Is the arbiter turned on Is it correctly connected to the PC using a crossover cable or correctly connected to...

Page 27: ...e field blank CAUTION Each device on your network including computers routers controllers brains and so on musthaveauniqueIPaddress FailuretoassignuniqueIPaddressesmaycausecatastrophicnetwork or hardw...

Page 28: ...ng an Existing Control Engine for Redundancy on page 37 of this guide 1 Make sure you have connected the hardware as described in Chapter 2 Connecting the Hardware 2 Make sure you have completed all o...

Page 29: ...r on page 17 and Assigning an IP Address to the Arbiter on page 21 The completed dialog box will look something like this 8 For Controller Port Software Retries and Software Timeout use the default se...

Page 30: ...make sure the secondary address for Controller 2 is odd such as 172 22 22 3 Also the two IP addresses must be sequential such as the examples 172 22 22 2 and 172 22 22 3 To assign the secondary IP fo...

Page 31: ...for networking information 7 Enter a secondary IP address and subnet for ENET 2 of Controller 1 The ENET 2 port is used to connect the controllers to each other The recommended settings for ENET 2 for...

Page 32: ...hapter Chapter 4 Creating a Strategy with Controller Redundancy Checking the System Use System Checkout in PAC Redundancy Manager to confirm that your system is configured and connected correctly CAUT...

Page 33: ...etected follow the on screen directions to correct the problem Remember that a strategy must be running on the controller in order for the check to work 3 Click System Checkout again If your system is...

Page 34: ...CHECKING THE SYSTEM SNAP PAC Redundancy Option User s Guide 30...

Page 35: ...he strategy programmer to reduce the communication overhead of synchronization only persistent redundant variables and I O are synchronized and by using sync blocks synchronization is delayed until a...

Page 36: ...hart to any I O or persistent redundant variables until it encounters a sync block All the various kinds of writes that occur in a chart after a sync block are not executed until the next sync block i...

Page 37: ...g sync blocks to indicate where in the logic you want the synchronizations to occur Creating a PAC Control strategy for controller redundancy includes the following tasks Step 1 Enabling the PAC Contr...

Page 38: ...Guide 34 The Persistent Redundant option becomes available on the Add Edit Variable dialog box Redundant variables are persistent variables that are replicated to a backup controller when one is avail...

Page 39: ...PAC Control 1 Start PAC Control by clicking the Start button and selecting Programs Opto 22 PAC Project PAC Control Pro The PAC Control main window opens 2 Click the Open Strategy button on the toolba...

Page 40: ...ant controllers You can either add to your strategy the control engine you created in Chapter 3 see Creating a Control Engine for Controller Redundancy on page 24 or you can configure a control engine...

Page 41: ...Set Active Only one control engine can be active at any time If only one control engine is listed it automatically becomes the Active Engine Configuring an Existing Control Engine for Redundancy Use t...

Page 42: ...s name and then click Modify The Control Engine Configuration dialog box appears 5 Under System Type select Redundant Controllers New Settings options appear 6 Using the IP addresses you created earl...

Page 43: ...ilable backup controller whenever synchronization occurs For optimal performance of your redundant system best practice is to always use transactional charts Also keep in mind to use redundant variabl...

Page 44: ...downloaded again A persistent redundant variable s value remains the same until one of the following events occurs The value is changed with PAC Control Debugger or other client A strategy with a diff...

Page 45: ...able select the type and under Initialization select Persistent Redundant 7 Click OK The Add Variable dialog box closes and the new variable appears in the Configure Variables dialog box Step 4 Design...

Page 46: ...ed until a sync block is encountered at which point the data generated by a transactional chart is synchronized in both the active and backup controllers Each transaction starts with the first write o...

Page 47: ...ransaction ends at the next sync block Transaction starts Transaction ends Sync block Short delay Using a redundant bake timer variable maintains the proper baking time If a long delay were used inste...

Page 48: ...Subroutines may not contain sync blocks However a subroutine may perform operations on redundant objects Called charts are not supported Call Chart is not supported but Start Chart is You cannot do b...

Page 49: ...l when the controllers are synchronized An operator changes a value for a persistent redundant variable in PAC Control Debug mode or in PAC Display Runtime Only the changed persistent redundant variab...

Page 50: ...blocks of the same type 6 When you have finished using the tool click the right mouse button click another tool in the toolbar or press ESC To use sync blocks in a chart s logic you ll need to name th...

Page 51: ...re 53 Managing Memory 56 Using Advanced Functions 58 Using Controller Redundancy Debug Options 60 Arbiter Status LEDs and Blink Codes 61 Resetting the Arbiter 62 Checking System Status When you have c...

Page 52: ...It also displays status messages which you can use to troubleshoot your system See the sections below Redundant System Status Messages and Redundant System State Machine Redundant System Status Messa...

Page 53: ...viously active controller Maintenance Used for certain operations such as download a strategy or installing firm ware Non Qualified Backup The controller is attempting to become qualified copying firm...

Page 54: ...to read this memory location If this flag is TRUE on boot the controller will enter maintenance mode To set the Enter Maintenance Mode flag to TRUE write the value 0x4D41494E hex or MAIN ASCII to memo...

Page 55: ...troller before telling the backup to become active Otherwise you might have two simultaneous active controllers Because turning off power to a device that is doing a flash write may cause corruption o...

Page 56: ...first time see Assigning an IP Address to the Arbiter on page 21 1 In PAC Redundancy Manager under General Tools on the main window click Change IP Address The Change IP Address dialog box opens 2 In...

Page 57: ...PAC Redundancy Manager Installing Firmware to the Controllers There are two different ways in PAC Redundancy Manager to install firmware to the controllers The default and recommended method Running...

Page 58: ...backup qualification process 1 Turn off either the arbiter or the other controller 2 Under Arbiter Management on the PAC Redundancy Manager click Install Firmware 3 On the Install Firmware window sele...

Page 59: ...AC Redundancy Manager click Install Firmware The Install Firmware window appears 2 Select Arbiter in the top pane 3 Under Arbiter Device select Selected Arbiter 4 Under Firmware browse to the firmware...

Page 60: ...er s memory can disrupt a running system During the update thecontrollermustbeplacedintoMaintenancemode duringwhichtimeitcannotbetheActivecontroller IfthecontrolleriscurrentlyActive thestrategywillbes...

Page 61: ...Store Configuration to microSD card Erase Configuration from microSD card Erase Firmware from microSD card Erase Strategy microSD card Copy microSD card to Flash IMPORTANT Before using the microSD ca...

Page 62: ...anced functions are for diagnostic and troubleshooting purposes Misuse of these features can have unintended consequences If you are unsure about how to use these features please contact Opto 22 Produ...

Page 63: ...or more information on maintenance mode see D below C Exit Maintenance and become Active Exits maintenance mode when there is a strategy loaded For more information on maintenance mode see D below D E...

Page 64: ...ld be used when you have connected and configured an arbiter and at least one controller With this setting PAC Control will select which controller to use for downloading and debugging If possible it...

Page 65: ...tgoing serial activity RX Incoming serial activity System Status LEDs LED Indicates ARB Arbiter Status Off arbiter has failed or is not powered Red arbiter has failed Orange arbiter is starting Green...

Page 66: ...s until the STAT LED turns solid green and then immediately release the button Don t hold it down too long The arbiter restarts IP address is reset to 0 0 0 0 and subnet mask to 255 255 255 0 CAUTION...

Page 67: ...han five seconds but longer than the time needed to restore the default settings the arbiter will restart in failsafe bootloader mode which is indicated by the STAT LED blinking green 7 times quickly...

Page 68: ...RESETTING THE ARBITER SNAP PAC Redundancy Option User s Guide 64...

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