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Saia-Burgess Controls AG

User Manual Standby System

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Document 27-645

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Edition E

NG 02

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2017-04-26

PCD2.M4x60

Contents

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Technical Information

Data Synchronization and Switchover (Synchronous) .......................... 4-1

Data Synchronization and Switchover (Asynchronous) ........................ 4-1

LED States ............................................................................................ 4-1

State Machine ....................................................................................... 4-2

4.5 Troubleshooting

..................................................................................... 4-2

...................................................................................................... A-1

Instructions for connecting Saia-PCD

controllers to the internet ......... A-1

.................................................................................................. A-2

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Summary of Contents for PCD3.M6880

Page 1: ...Document 27 645 Edition ENG02 2017 04 26 User Manual Saia PCD Standby System redundant automation solutions ...

Page 2: ... PG5 Project Manager View 2 5 2 3 Process Data Synchronization 2 6 2 4 Media Exchange 2 8 2 5 Configuration 2 11 2 5 1 Standby System Configuration dialog box 2 11 2 5 2 Redundant Device Configuration 2 14 2 5 3 Creating a Default RIO Configuration 2 16 2 5 4 Error and Warning Messages 2 16 2 5 5 Downloading the Device Configuration 2 19 2 6 Programming 2 20 2 6 1 CPU0 Control Program 2 20 2 6 1 1...

Page 3: ...2 0 4 Technical Information 4 1 Data Synchronization and Switchover Synchronous 4 1 4 2 Data Synchronization and Switchover Asynchronous 4 1 4 3 LED States 4 1 4 4 State Machine 4 2 4 5 Troubleshooting 4 2 A Annex A 1 Icons A 1 A 2 Instructions for connecting Saia PCD controllers to the internet A 1 A 2 Contact A 2 ...

Page 4: ... 2015 11 27 2016 03 11 2017 04 03 2015 11 27 2016 03 16 2017 04 03 First edition PCD3 Fxxx 26 857 new footer ENG02 2017 04 26 2017 04 26 Ch3 1 more possible failures listed 0 2 Trademarks Saia PCD is a registered trademark of Saia Burgess Controls AG Technical changes are subject to the state of technology Saia Burgess Controls AG 2017 All rights reserved Published in Switzerland ...

Page 5: ...ds the duplication of the inputs outputs and the sensors actuators Programmable remote I Os create intelligent decentralized nodes to provide additional reliability The network uses standard Ethernet components and can run over a standard Ethernet TCP IP network along with other services Easy engineering and commissioning using the PG5 Project Manager to auto matically generate the project Uninter...

Page 6: ...on Standby System Overview 1 2 1 Ethernet SCADA 1 SCADA 2 IP network with fibre optic ring Secondary Primary Process I O Process I O SCADA system Standby Controllers PCD3 M6880 Smart RIOs PCD3 T668 Typical layout of a redundancy system with two PCD3 M6880 Standby devices and PCD3 T668 Ethernet Smart RIOs ...

Page 7: ...ontrol in the event of a fault on the active device Active PCD The PCD whose CPU1 is in Active Mode running the redundant program and controlling the inputs outputs PCD3 T668 RIOs Standby PCD The PCD whose CPU1 is in Standby mode It does not run the redundant program and the outputs PCD3 T668 RIOs are not controlled by this device Main CPU CPU0 of the Primary or the Secondary PCD which runs the no...

Page 8: ...terrupted switching from the active to the standby PCD The Redundant CPU1 has two inde pendent Ethernet interfaces The ETH 2 interface is reserved exclusively for operating the PCD3 T668 RIO stations The PCDs also synchronize their pro cess data via the same interface For security reasons we recommend set ting up this network as a ring structure with specific network components from third party pr...

Page 9: ...0 from Hirschmann However the networks can also be set up with standard components in a star structure A shared physical network for the remote I Os and management systems is also possible but availability of the system will be reduced accordingly Ethernet SCADA 1 SCADA 2 Network redundancy with fiber optical ring Secondary Primary Process I O Process I O Standby Controller PCD3 M6880 SCADA System...

Page 10: ...tion ENG02 2017 04 26 Order details Standby System Overview 1 6 1 1 4 Order details PCD3 M6880 Modular PCD3 standby controller with 2 Ethernet TCP IP ports and a coprocessor for standby operation PCD3 T668 Smart RIO for standby system for connection to the PCD3 M6880 CPU1 ...

Page 11: ...s of the main CPU0 can be different in the primary and secondary PCD3 M6880 CPU0 has the same capabilities as a standard PCD e g PCD3 M5560 Local I Os in the PCD s slots and the I O expansion modules are controlled by CPU0 External systems and devices SCADA systems web browsers and other external devices communicate only with CPU0 CPU0 s internal PCD media F R T C DB are not synchronized between t...

Page 12: ...s full duplex auto sensing auto crossing ETH1 ETH2 x 2 port switch RS 485 on terminal block Port 2 or RS 485 Profibus DP Slave Profi S Net on terminal block Port 2 up to 115 kbit s up to 187 5 kbit s Optional communication interfaces I O slot 0 PCD3 F1xx modules for RS 232 RS 422 RS 485 and Belimo MP Bus Yes No I O slot 0 3 up to 4 modules or 8 interfaces PCD3 F2xx modules for RS 232 RS 422 RS 485...

Page 13: ...anual switchover command is executed This is only possible if the Primary device does not have priority the Primary device has priority option must be No Data Synchronization and Supervision Keep Alive Data Synchronisation and Program Cycle The used PCD medias R F T C DB TX in the redundant CPU1 are cyclically synchronized between the active and the standby PCD The synchronization time for all PCD...

Page 14: ...with Standby Controllers Can be used as a simple local I O station or an intelligent programmable I O station Can be programmed with the PG5 Important or timecritical tasks can be processed directly in the RIO The RIO s user programs are managed centrally by the Smart RIO Manager PCD and downloaded to the RIOs automatically Data exchange uses the efficient Ether S IO protocol Simple configuration ...

Page 15: ...g auto crossing Default IP configuration IP address 192 168 10 100 Subnet mask 255 255 255 0 Default gateway 0 0 0 0 USB port for configuration and diagnostics yes Program memory 128 kByte Web server for configuration and diagnostics yes Web server for user pages yes On Board file system for web pages and data 512 kByte BACnet or LonWorks no On Board interrupt inputs 2 On Board RS 485 interface ye...

Page 16: ...g the data to be exchanged between the CPUs 1 Create a new Project Use Project Manager s Project New Project command to create a new project Check the Create Device option A single PG5 project can contain one standby system one primary and one secondary device If you have more than one standby system on the same network then you must create a new PG5 project for each standby system If you are usin...

Page 17: ...be displayed next Select the device type PCD3 M6880 CPU with Standby support This is the primary device so it is assigned the name 1 Primary by default but you can rename it if you like A standby project contains 3 devices by default these are named 1 Primary 2 Secondary and 3 Redundant The 1 2 and 3 prefixes are used only to define the order of the devices in the Project Tree The devices can also...

Page 18: ...define the media for transfer between CPU0 and CPU1 on the Primary and Secondary devices These media are also transferred between the devices see Media Exchange According to the application you may want to use separate to and from symbol files for the data transfer between CPU0 and CPU1 To do this select the Separate symbol files option It will then use three symbol files ToRedSymbolsPrimary sy5 T...

Page 19: ... create these files yourself or restore copy or import them from another project If there are any files missing messages will be shown in Project Manager s Messages window see Configuration Error and Warning Messages This message box is also shown if you later rename a device or file it will always ask if you want to create a missing device or file You can always rename or create the devices and f...

Page 20: ... the RIOs in the Project Tree Each device defines its own symbol file s see Media Exchange The Primary and Secondary devices reference the symbol files of the Redundant device The Redundant device references the symbol files of the Primary and Secondary devices The symbol file references are shown using a relative path name directory_name file_name sy5 where means the parent directory Here s the v...

Page 21: ...e first and last used addresses for each media type All media between the first used address and the last used address are transferred even if the data is not used by the program so try to keep the addresses consecutive If using dynamic addressing keep the dynamic address ranges to a minimum the device s Build Options to assign the address ranges Use the Device Advanced Clean Files command to rese...

Page 22: ...tually used by the program If media are accessed using the Index Register these addresses may not be taken into account if they are at the end of the address range If the Index Register is used always ensure that the indexed addresses are within the ranges shown in the Redundancy Synchronization Data table If not define and reference an address at or beyond the end of the indexed range to ensure t...

Page 23: ... used When a value is written to one of the media addresses defined in this file the value is transferred to the other CPUs in the ACTIVE and the STANDBY devices The procedure is as follows 1 CPU0 of the ACTIVE device modifies the media values of symbols defined in RedSymbols sy5 either by the user program an S Bus telegram a Web page etc 2 CPU0 transfers the modified media values to CPU1 of the A...

Page 24: ...efault file names which are created for you automatically when the project is created ToRedSymbolsPrimary sy5 Defines data transferred to the Redundant CPU1 from the Primary CPU0 ToRedSymbolsSecondary sy5 Defines data transferred to the Redundant CPU1 from the Secondary CPU0 FromRedSymbols sy5 Defines data transferred to both the Primary and the Secondary CPU1 from the Redundant CPU1 The FromRedSy...

Page 25: ...ted as an array of values between the first and the last address Dynamic addresses can be used but this is less efficient because the addresses may not be consecutive so single addresses instead of an array are transferred and there may be alignment problems which require a Device Advanced Clean Files Symbol Information Files operation If there is an alignment problem you will receive the Redundan...

Page 26: ...s a PCD3 M6880 redundancy device then the Standby Sys tem Configuration branch is shown at the top of the Project Tree Double click on this to open the Standby System Configuration dialog box This dialog box is also shown when you first add a PCD3 M6880 Standby Device to your project This is where the device and symbol file names for the Standby project are de fined With the Single symbol file opt...

Page 27: ...tails Primary Device CPU0 This is CPU0 of the first PCD3 M6880 Primary device name The name of the PCD3 M6880 Primary device The default is 1 Primary Press the browse button to select an existing PCD3 M6880 device Primary device symbol file name For Separate symbol files only The name of the global symbol file that de fines the media transferred between CPU0 and CPU1 of the Primary device This is ...

Page 28: ... between CPU1 and CPU0 of the primary and the secondary devices For Sin gle symbol files the default file name is RedSymbols For Separate symbol files the default file name is FromRedSymbols sy5 Set Defaults button Press this to set the default device and file names The same defaults are used when a new redundancy system is first created by adding a PCD3 M6880 de vice to the project OK button When...

Page 29: ...ndant CPU which are used by the Primary and Secondary devices There is a Redundancy section in the PCD3 M6860 CPU1 properties Primary device has priority If Yes then the primary device will be the active device whenever possible and manual switchover is disabled If No then either device can be the active device and manual switchover is enabled Keep alive timeout ms If the standby CPU1 device has n...

Page 30: ...mber Fixed as XOB 31 If programmed this XOB is executed on CPU1 when the Standby PCD takes over control of the system and becomes the Active PCD Ethernet Port IP Settings The Redundant CPU1 s Ethernet IP ports are also configured from here Primary CPU1 IP Address The IP address of CPU1 in the Primary device This IP address is used to transfer the synchronization data between CPU1 in the Secondary ...

Page 31: ... is missing create a device with the correct name and the type PCD3 M6880 To create the device automatically open the Redundancy Configuration dialog box press OK and answer Yes to the Do you want to create message box Error 7000 Redundant device not found device_name The device does not exist in the project You cannot create a device with the type PCD3 M6880 CPU1 so open the Redundancy Configurat...

Page 32: ... Different IP addresses must be used Open the Redundancy Configuration dialog box and correct it Error 7007 Invalid Online Settings for Redundant device needs Sta tion 253 Auto Station No device_name This is possible because the Online Settings does not know what the device type is and cannot stop the user changing the settings Open the Online Set tings for the redundant device and correct them Er...

Page 33: ...g 7102 Invalid S Bus Station Number in Online Settings is n should be n The S Bus station number on the Online Settings does not match the S Bus station number on the device configuration Warning 7103 Invalid IP Address in Online Settings is xxx xxx xxx xxx should be xxx xxx xxx xxx The IP address in the Online Settings does not match the IP address in the device configuration Warning 7104 Invalid...

Page 34: ...on for both CPUs 0 and 1 in the device Repeat this for the primary and secondary devices Once the configuration has been downloaded open the Online Settings and set PGU mode No and Auto Station No Now you can either use two local S Bus USB connections or an S Bus TCP IP connection for communications with the two devices Using two USB connections Two USB connections can be used to connect locally t...

Page 35: ...image See CPU1 Redundant Program 2 6 1 CPU0 Control Program The CPU0 program is a non redundant program that always runs on both PCDs There are no restrictions on what this program can do It can access local I Os use asynchronous communications and connect to a SCADA system The execu tion of this program is not synchronized with the Standby device For data ex change between CPU0 and CPU1 see Media...

Page 36: ...en create alias symbol names from them which are the same in both devices Using the Common Files branch In Project Manager create the files e g the IL or Fupla program files in the Com mon Files branch instead of the device branch Then drag and drop each file onto the Primary or Secondary device s Program Files branch This creates a refer ence to the file in the Common Files directory Common Files...

Page 37: ...mmand To use the same program files first select the Action Store path to file do not copy it see the picture below If this is not selected then Add Files will make new copies of the files which is not what you want From the Add Files dialog box navigate to the Primary device s directory and select the program file or select multiple pro gram files by holding Shift or Ctrl key down before clicking...

Page 38: ...m Document 27 645 Edition ENG02 2017 04 26 Programming Diagnostic 2 23 2 Here is a project with the same programs for the Primary and Secondary devices that uses two Common Files and global symbol files for symbols with different values in each device ...

Page 39: ... only on the ACTIVE PCD and controls the remote IOs via PCD3 T668 RIOs The redundant program is always the same on both PCDs Restrictions CPU1 cannot use any communications S Bus master Modbus BACnet FTP etc except ESIO for the RIO network and data synchronization CPU1 has no direct access to IO modules or Flash memory modules Communications with a SCADA system or other external system can run onl...

Page 40: ...n Number is always set to 253 and the IP Address or Host Name is filled in with the IP address of the Primary or the Secondary device whichever is the AC TIVE device If another channel is used then it will go online the actual Online Settings so en sure that the IP address of the Primary or the Secondary device is used Tips Connecting to CPU1 with S Bug S Conf or the Watch Window If you use the On...

Page 41: ... over 2 6 3 Switchover XOB 31 XOB 31 if present is executed on CPU1 when the Standby PCD takes over con trol of the system and becomes the Active PCD 2 6 4 System Symbols Each of the three redundancy devices has the following diagnostic System Sym bols which can be used in the program After the first build of the program you can find the symbols on the System tab of the Symbol Editor See the Diagn...

Page 42: ...ialog box shows the four CPUs the Primary CPUs 0 and 1 and the Second ary CPUs 0 and 1 The Primary and Secondary CPU 1 runs the redundant pro gram which is the same on both devices The Primary and Secondary CPU 0 may run different programs For each CPU the CPU Status Run Stop Halt etc the Build Status Build OK Build required and the Program Status of the program already in the CPU Pro gram up to d...

Page 43: ...the Standby device then to the Active device and the Active device remains active after it is reset Clear Media R F T C checkbox All Registers Flags Timers and Counters are reset to 0 before the downloaded program is run If using Media Mapping for Outputs on CPU 0 then checking this option will cause all Outputs to be reset Keep existing RAM DB and RAM TEXT data checkbox The values in existing DBs...

Page 44: ...ocol channel or is Password Protection is active in the connected PCD Connect failed Unable to connect to the CPU or PCD Check it has power and is correctly connected to the PCD This can also occur if the Online Settings are wrong or if the PCD is incorrectly configured with a wrong station number or IP address etc Try connecting in PGU mode using S Bug or the Online Configurator and display the c...

Page 45: ...ry CPU 1 used by each CPU 1 for the sync data transfer is not the same as that configured in the Redundancy device s Device Configuration This could be because of incorrect values on the Device Configurator or because the connected CPU 1 contains a different configuration Correct the IP address and or download the new configuration To download the configuration to the Redundant CPU 1 you must down...

Page 46: ...3 M6880 CPU1 Standby only works with these PCD models Wrong S Bus station number The connected PCD s S Bus station number is not the same as the station number configured in the Device Configurator Either the PCD s configuration is wrong or you are connected to the wrong PCD This cannot occur if S Bus is being used for the communications channel and PGU mode and Auto Station are both No Check the ...

Page 47: ... Message HALT Meaning Red FAIL xxx Y N Caused by Redundancy failure xxx 0 General error 1 Redundancy not configured 2 Out of memory 3 Media transfer error 4 CPU Keep alive timeout 5 CPUs have different configurations 6 Size of media mapping incorrect 7 No data transfer configured 8 Incompatible data IDs 9 Media transfer error 2 Red Media Map FAIL Y Redundancy media map configuration error Red CPU ...

Page 48: ...s NO Read only 0 4 0 STARTUP 1 IDLE 2 STANDBY 3 ACTIVE Redundancy 4 ACTIVE Non Redundancy StatusText NO Read only STARTUP IDLE STANDBY ACTIVE Same as Status but as text StandbyOrActive NO Read only 0 1 0 Standby 1 Active Redundancy NO Read only 0 1 0 No Redundancy 1 Redundancy DataSyncOK NO Read only 0 1 Data Synchronization 0 FAILED 1 OK ProgSyncOK NO Read only 0 1 Program Synchronization 0 FAILE...

Page 49: ... NO REDUNDANCY 1 REDUN DANCY 1 Data sync is working both CPU1s have the same program standby switching can oc cur If 0 then standby control is not available 3 S STANDBY DataSyncOK 0 FAILED 1 OK 0 Sync communications between the two CPU1s has failed 1 it s working 4 S STANDBY ProgSyncOK 0 FAILED Different 1 OK Same 0 programs in both CPU1s are different and sync cannot occur 1 programs are the same...

Page 50: ...shown on the All Publics tab of the RIO pro gram s Symbol Editor in the group RIO Offset System Symbol Name Values 0 RIO GlobalDiagnostic 0 no diagnostic flags set 1 a diagnostic flag is set 1 RIO TelegramLost 0 no telegrams lost 1 one or more telegrams lost 2 RIO SendError 0 no error 1 failed to send or out of resources 3 Reserved 4 Reserved 5 RIO ActiveManager 0 Primary 1 Secondary 6 RIO Seconda...

Page 51: ...M6880 show the standby status Standby State RUN LED State Error LED State IDLE Blink 500ms STANDBY Blink 2 5s OFF ACTIVE Redundancy OFF ACTIVE Non Redundancy ON normal state of the RUN Led on a PCD If CPU0 is in Conditional RUN Led blinks 2 5sON 500ms OFF STOP Led blinks 500msON 2 5s OFF Saia Burgess Controls AG User Manual Standby System Document 27 645 Edition ENG02 2017 04 26 Data Synchronizati...

Page 52: ...UN but the Standby PCD is in HALT The redundancy configuration is not the same on both PCD s Download the same configuration to both PCD s Saia Burgess Controls AG User Manual Standby System Document 27 645 Edition ENG02 2017 04 26 State Machine troubleshooting System overview 4 2 4 ...

Page 53: ...binet of PGU connector However it is better to use a grounding wrist strap with its cable permanently attached to the system s negative pole This sign accompanies instructions that must always be followed A 2 Instructions for connecting Saia PCD controllers to the internet When Saia PCD controllers are connected directly to the internet they are also a potential target of cyber attacks For secure ...

Page 54: ...entral 41 26580 30 00 Phone Saia PCD Support 41 26580 31 00 Fax 41 26580 34 99 Email support support saia pcd com Supportsite www sbc support com SBC site www saia pcd com International Represetatives SBC Sales Companies www saia pcd com contact Postal address for returns from customers of the Swiss Sales office Saia Burgess Controls AG Service Après Vente Bahnhofstrasse 18 3280 Murten Switzerland...

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