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Chapter

Monitoring and Troubleshooting Your
ControlNet PLC-5 Backup System

Chapter Objectives

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ControlNet PLC-5 Backup-Specific
Major Fault Error Codes

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If you see fault code:

Which indicates this fault:

Take this corrective action:

230

System attempted transition to Run mode with processor
in Invalid backup state.

Change from the Invalid backup state to the No Control backup
state before transitioning into Run mode. Refer to the Invalid
backup state troubleshooting table later in this chapter.

231

Bypassed qualification (may occur during race condition
when both processors attempt to go into Run mode at the
same time).

Transition the PLC-5 processors into Run mode one at a time.

232

Both processors attempted to be primaries.

Check all media for broken cables, loose connectors, missing
terminators, etc..

233

ControlNet configuration invalid on transition into Run
mode.

Reconfigure the ControlNet channel.

234

Failed Qualification.

Refer to the qualification major faults troubleshooting table later
in this chapter.

Содержание ControlNet PLC-5

Страница 1: ...User Manual ControlNet PLC 5 Hot Backup System Includes Cat No 1785 CHBM Allen Bradley...

Страница 2: ...r installation theAllen BradleyCompany cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Allen Bradley Company with respect...

Страница 3: ...SURFHGXUHV IRU WKH EDFNXS V VWHP Who Should Use This Manual HIRUH RX UHDG WKLV PDQXDO RU DWWHPSW WR XVH WKH RQWURO1HW 3 EDFNXS V VWHP RX VKRXOG EH IDPLOLDU ZLWK WKH XVH DQG RSHUDWLRQ RI RQWURO1HW 3 SU...

Страница 4: ...perating the backup system E Application Guidelines reference information on the ControlNet backup module for users familiar with the Allen Bradley 1785 BCM systems F Comparison to the 1785 BCM System...

Страница 5: ...ng Your Backup System 3 2 Configuring With a Single Control Application 3 2 Configuring With Differing Applications 3 7 Advanced Configuration Options 3 12 Synchronous and Asynchronous Program Scannin...

Страница 6: ...nel C 7 Inhibiting Data Table Crossloads C 7 Data Table Crossload Diagnostics C 8 Performing Data Table Crossloads Via Your Applications C 8 Appendix D Program Synchronization Chapter Objectives D 1 P...

Страница 7: ...p guard your application against shutdowns caused by the programmable controller The backup option is used where you must transfer the control of the process to a secondary system without interrupting...

Страница 8: ...ControlNet the processors communicate or handshake with each other exchanging status information on their operational states If the primary processor faults or is otherwise unable to continue control...

Страница 9: ...rison status file comparison Data file crossloading from the primary to the secondary processor may include the transfer of integer values floating point values timers counters PID values and others y...

Страница 10: ...hover Switchover Switchover is what occurs when the secondary processor assumes control of the process thus becoming the primary processor Several conditions can cause this to happen critical failures...

Страница 11: ...wo 1785 CHBM A ControlNet backup cartridges one for each PLC 5 processor two 1771 chassis one for each PLC 5 processor two 1771 power supplies one for each chassis You can elect to use redundant power...

Страница 12: ...tridge inserted into the PLC 5 EEPROM memory cartridge slot to enable backup functionality The ControlNet backup cartridge contains EEPROM memory cartridge functionality i e the cartridge can also be...

Страница 13: ...your ControlNet network 2 Install each PLC 5 processor into a separate 1771 chassis 3 Insert the 1785 CHBM ControlNet backup cartridge into the EEPROM slot of each PLC 5 processor Note that the power...

Страница 14: ...the steps in the section of this chapter entitled Configuring With Different Applications Configuring With a Single Control Application This section assumes that you have already developed your contr...

Страница 15: ...ars 4 For each entry under the Connection Type column double click on Exclusive Owner choose Redundant from the pull down menu and press Enter Configure Handshaking Messages With RSNetWorx Within your...

Страница 16: ...will use an RPI value of 5 In general the RPI value must be no less than the NUT value but less than 2 times the NUT value This value must be the same in both PLC 5 processors 4 In the Message Size f...

Страница 17: ...node corresponding to your I O adapter and choose Auto Module Selected Device All 1794 non discrete I O modules on your ControlNet network are added to your configuration as pending map entries 2 Ent...

Страница 18: ...screen appears with the Configure tab selected 8 Set the following Backup File Enter an unused data file number This creates a 200 word integer file to be used as the ControlNet Backup Configuration a...

Страница 19: ...tandalone processor was processor 1 change the value from 1 to 2 4 From the Comms menu choose Download to download the project to the new processor 5 When prompted to decide whether you wish to keep t...

Страница 20: ...6 Configure the hot backup parameters on the second processor and save the project Reconfigure ControlNet I O on the First PLC Processor Reconfigure all ControlNet I O adapters and modules that will...

Страница 21: ...ou This number indicates the node number from which you will receive the Receive scheduled message In your ControlNet backup system the odd node will receive the message from the even node and vice ve...

Страница 22: ...e 8 Record the Send and Receive message numbers from the odd processor node below Send message number __________ Receive message number __________ You will use these numbers later in the configuration...

Страница 23: ...7 Click on the Hot Backup icon under the Controller folder to launch the Hot Backup Configuration utility The ControlNet Hot Backup screen appears with the Configure tab selected 8 Set the following...

Страница 24: ...tab of the ControlNet Hot Backup screen in RSLogix 5 Simply choose the Odd PLC Node from the Designated Primary pull down menu Note You must make this selection for both processors and they must be in...

Страница 25: ...and secondary controllers to operate as fast as they possibly can without attempting to synchronize with each other This mode of operation should be used when the divergence of programs I O tables and...

Страница 26: ...e Checks You can perform equivalence checking to verify that selected areas in both the primary and secondary PLC processors are identical You can enable various equivalence checks from the Configurat...

Страница 27: ...he Crossload tab of the ControlNet Hot Backup screen To crossload timer counter or PID values simply click on the respective button The crossload is performed as soon as you click on the appropriate b...

Страница 28: ...secondary PLC processors You can press the Clear button to reset these values Qualification Error Reason If the qualification of the system fails the Qualification Error Reason indicates the reason w...

Страница 29: ...chapter in the section entitled Create and Download the Project for the Second PLC Processor then you can complete this processor to processor download The steps outlined there ensure that a new diff...

Страница 30: ...Publication 1785 6 5 24 February 1999 3 18 Installing and Configuring Your ControlNet PLC 5 Backup System...

Страница 31: ...p Specific Major Fault Error Codes 7KH 3 SURFHVVRU VWRUHV PDMRU IDXOW FRGHV LQ ZRUG RI WKH SURFHVVRU VWDWXV ILOH 6 7KH IROORZLQJ WDEOH OLVWV QHZ PDMRU IDXOW FRGHV VSHFLILF WR WKH RQWURO1HW RW DFNXS SU...

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Страница 33: ...connection in the I O map table 5 words long 4 Send handshake connection wrong size Make the handshake connection in the I O map table 5 words long 5 Node address number wrong Enter the odd node numb...

Страница 34: ...alence check if desired Make Force Tables identical in each processor 6 Failed Qualification Equivalence check Configuration parameters in processor status file different Disable processor status file...

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Страница 36: ...5 8 Output Ownership Invalid Count word This word indicates how many connections are not owned by this processor Primary backup state only This value is 1 when the processor is in the Secondary backup...

Страница 37: ...the reason why the configuration attempt was unsuccessful or whether the configuration parameters were overwritten because the system went into Run mode as a secondary system 6 Operation mode word inv...

Страница 38: ...failed due to keyswitch change to Program mode 10 Qualification failed due to Run mode inhibited 11 Qualification failed due to processor uploading or downloading program 12 Qualification failed due t...

Страница 39: ...alification crossload and on demand when setting the appropriate bit in word 33 56 User Defined Crossload File 2 You can select a single file number written in this word to be crossloaded during the Q...

Страница 40: ...3XEOLFDWLRQ HEUXDU 4 10 Monitoring and Troubleshooting Your ControlNet PLC 5 Backup System...

Страница 41: ...2 5 oz Environment Operating Temperature 0 to 60 C 32 to 140 F Storage Temperature 40 to 85 C 40 to 185 F Relative Humidity 5 to 95 without condensation Shock Testing Operating 15 g peak acceleration...

Страница 42: ...3XEOLFDWLRQ HEUXDU A 2 Specifications...

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Страница 45: ...ed Designated Primary Disabled Maximum Program Scan Time 0 Qualification Delay 0 Crossload File 1 0 Crossload File 2 0 Crossload File Low 0 Crossload File High 0 No Control Backup State When a valid b...

Страница 46: ...checked for validity before being accepted Note If a newly entered configuration parameter is invalid the backup system uses the previous configuration values Lonely Primary Backup State The Primary...

Страница 47: ...Q SDUDPHWHU WR DQ LQYDOLG YDOXH WKH 3 RQWURO1HW EDFNXS V VWHP WUDQVLWLRQV LQWR WKH QYDOLG EDFNXS VWDWH 7KLV VHFWLRQ GHVFULEHV WZR EDFNXS VWDWH WUDQVLWLRQV 4XDOLILFDWLRQ DQG 6ZLWFKRYHU Qualification Qu...

Страница 48: ...ation The first case is when a reconfiguration of the ControlNet channel occurs When this occurs all connections are terminated and must be reestablished the 10 second wait allows the connection to be...

Страница 49: ...declares a major fault There are 6 different areas in which equivalence checking can be performed Program File Structure and Program Files This checksum is calculated for all the Program files with t...

Страница 50: ...sum are I O Force Table values Extended Force Table values Force Status is forcing enabled and are forces present No SFC information is included in the Force Tables checksum Also note that you cannot...

Страница 51: ...quivalence check Once all the edits are tested and placed into both PLC 5 systems you can reenable the equivalence check Word 49 in the ControlNet Backup Configuration and Status file gives you equiva...

Страница 52: ...lification Data Table crossload fails qualification also fails and a major fault is declared for the qualifying system Refer to Chapter 4 for descriptions of specific major fault codes Transition to R...

Страница 53: ...sloaded into the qualifying system closely match the values in the primary system The Qualification State Data Table crossload does not occur if the Data Table Structures are not the same If you want...

Страница 54: ...tion The ControlNet backup state was Invalid backup state Refer to Chapter 4 Troubleshooting for information on fixing a Qualification major fault Switchover Switchover occurs when one of the processo...

Страница 55: ...ced Switchover allows you to switch over a qualified PLC 5 ControlNet backup system at any time You activate a Forced Switchover by writing a non zero value into the Forced Switchover word word 31 of...

Страница 56: ...condary systems there will be a bump in the outputs when the new primary processor takes control of the outputs There are features in the PLC 5 ControlNet backup system which minimize the divergence o...

Страница 57: ...switchover The following events can cause a Timeout Switchover Primary PLC 5 system failure Loss of power to the primary PLC 5 system Problems with the ControlNet network which causes loss of the han...

Страница 58: ...3XEOLFDWLRQ HEUXDU B 16 Backup States...

Страница 59: ...its own data table Over time the data table values may diverge between the primary processor and the secondary processor due to such things as internal timer differences or asynchronous events such as...

Страница 60: ...al between the two processors Also data table crossloading only crossloads data table data i e there is no mechanism to crossload Program file information It is up to you to ensure that the proper pro...

Страница 61: ...unter file types are crossloaded i e you cannot crossload a subset of Counter file types Also all file elements of each Counter file are crossloaded i e you cannot crossload a subset of file elements...

Страница 62: ...e crossloaded This shortens the time necessary to perform the crossload as well as preventing unwanted files from being crossloaded For example if there are 10 integer files that need to be crossloade...

Страница 63: ...and is in the On Demand Crossload Command word Qualification Crossloads There are two separate crossloads that are automatically performed during qualification These qualification crossloads are only...

Страница 64: ...crossload occurs while the processor is in Program mode For example if the Qualification data table crossload takes 10 seconds the data in the original data table file that was transferred is 10 secon...

Страница 65: ...f data is immediately written into the other processor s data table So no matter how long the data table crossload takes the data table elements which are crossloaded into the qualifying or secondary...

Страница 66: ...rossloads Via Your Applications On Demand data table crossloading greatly simplifies the whole crossloading procedure However you may have some special crossloading needs that are not covered by On De...

Страница 67: ...scan on a processor is finished housekeeping is delayed until a synchronization point is reached This synchronization point is the same for both processors Housekeeping is then performed at the same t...

Страница 68: ...l environment Second in Synchronous mode each program scan is always lengthened to be equal to the maximum program scan time Thus even when a particular program scan takes only a fraction of the maxim...

Страница 69: ...m Scan Time Exceed Counter word 48 in the ControlNet Backup Integer File is incremented You must zero out the Maximum Program Scan Time Exceed Counter for the Sync LED to turn from solid red to solid...

Страница 70: ...3XEOLFDWLRQ HEUXDU D 4 Program Synchronization...

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Страница 77: ...Publication 1785 6 5 24 February 1999...

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