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OPTO 22 SNAP PAC Redundancy Option User Manual

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SNAP PAC REDUNDANCY OPTION
USER'S GUIDE
Form 1831-180531—May 2018
43044 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 951-695-3080
Fax: 951-695-3017
Email: support@opto22.com
Web: support.opto22.com

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Summary of Contents for OPTO 22 SNAP PAC Redundancy Option

  • Page 1 SNAP PAC REDUNDANCY OPTION USER’S GUIDE Form 1831-180531—May 2018 43044 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 951-695-3080 Fax: 951-695-3017 Email: support@opto22.com...
  • Page 2 Specifications are subject to change without notice. Opto 22 warrants all of its products to be free from defects in material or workmanship for 30 months from the manufacturing date code. This warranty is limited to the original cost of the unit only and does not cover installation, labor, or any other contingent costs.

  • Page 3: Table Of Contents

    Checking the System..............28 SNAP PAC Redundancy Option User’s Guide...
  • Page 4 Resetting the Arbiter ..............62 SNAP PAC Redundancy Option User’s Guide...

  • Page 5: Chapter 1: Welcome

    1: 1: WelcomeChapter 1 1: Welcome Welcome to the SNAP PAC Redundancy Option User’s Guide. Inside you’ll find instructions on how to set up redundant controllers using two perfectly matched SNAP-PAC-S controllers. This guide ™ assumes that you understand fully how to use PAC Control and have some familiarity with ™...

  • Page 6: Ethernet Link Redundancy

    NOTE: The SNAP-PAC-SRA arbiter and the SNAP-RPSW redundant power switch can be purchased together in the SNAP PAC Redundancy Option Kit, part number SNAP-PAC-ROK. • One or more Opto 22 SNAP PAC Ethernet brain-based I/O units on the same Ethernet network as the controllers •...

  • Page 7: Redundancy Option Components

    • Signals the backup controller to qualify itself to be ready to take over as the active controller. The qualification process includes matching the firmware and strategy to those on the active SNAP PAC Redundancy Option User’s Guide...

  • Page 8: Snap-Rpsw Redundant Power Switch

    Professional software. Also included with PAC Project Pro, the PAC Redundancy Manager provides tools to configure the arbiter, monitor the devices in a redundant system, install firmware on the arbiter and the controllers, and more. SNAP PAC Redundancy Option User’s Guide...

  • Page 9: About This Guide

    Product Support If you have any questions about using SNAP PAC Redundancy Option, you can call, fax, or email Opto 22 Product Support. Product support is free. Phone:...
  • Page 10 A complete description of your hardware and operating systems, including: – switch configuration – type of power supply – types of I/O units installed – third-party devices installed (for example, barcode readers) • Specific error messages seen. SNAP PAC Redundancy Option User’s Guide...

  • Page 11: Chapter 2: Connecting The Hardware

    SNAP-PAC-S2s or two SNAP-PAC-S2-Ws, with firmware R9.0a or higher and loader R6.0a or higher – One or more Opto 22 SNAP PAC Ethernet brain-based I/O units on the same Ethernet network as the controllers – PAC Control strategy developed for use on the system’s two redundant controllers. See...

  • Page 12: Configuration Scenarios

    Scenario 2: Controller 1 and Controller 2 are in separate cabinets or rooms, and the arbiter is placed in the same cabinet or room as one of the controllers Scenario 3: Controller 1, Controller 2, and the arbiter are in separate cabinets or rooms SNAP PAC Redundancy Option User’s Guide...

  • Page 13: Connecting The Pac S-Series Controllers

    “Wiring the 10-pin Serial Connector on SNAP-PAC-S1 Controllers” on page 13 • “Wiring the 6-pin Serial Connector on the Arbiter” on page 14 For pinouts of SNAP PAC S-series controllers, see form 1592, the SNAP PAC S-Series User’s Guide. SNAP PAC Redundancy Option User’s Guide...

  • Page 14: Connecting Snap-Pac-S2 Controllers

    • It is usually easiest to use a two-pair (shielded) RS-485 data cable, as follows: - One pair for data - One pair for signal common - Shield for chassis ground. • Do NOT connect the signal common to chassis ground. SNAP PAC Redundancy Option User’s Guide...

  • Page 15: Connecting Snap-Pac-S1 Controllers

    2. Using ENET 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-wire” mode. SNAP PAC Redundancy Option User’s Guide...
  • Page 16 • It is usually easiest to use a two-pair (shielded) RS-485 data cable, as follows: - One pair for data - One pair for signal common - Shield for chassis ground. • Do NOT connect the signal common to chassis ground. SNAP PAC Redundancy Option User’s Guide...

  • Page 17: Wiring The 7-Pin Serial Connector On Snap-Pac-S2 Controllers

    When inserting and removing wire leads into this connector: 1. Completely depress the small orange tab for the appropriate opening with a small screwdriver. 2. While holding the tab down with the screwdriver, insert or remove the wire as needed. SNAP PAC Redundancy Option User’s Guide...

  • Page 18: Wiring The 6-Pin Serial Connector On The Arbiter

    6. Connect control wires from the arbiter to Side 1 and Side 2 on the switch. Now you are ready to configure the redundant system devices. Go the next chapter, Chapter 3: Configuring a Control System. SNAP PAC Redundancy Option User’s Guide...

  • Page 19: Power Connection Diagram

    CHAPTER 2: CONNECTING THE HARDWARE Power Connection Diagram red/white wire (+) black/white wire SNAP PAC Redundancy Option User’s Guide...
  • Page 20 CONNECTING POWER SNAP PAC Redundancy Option User’s Guide...

  • Page 21: Chapter 3: Configuring A Control System

    Configuration Protocol (DHCP) server, either assign a static IP address before connecting the device to the network (preferred), or disable the server. (These servers may respond to BootP requests and assign a dynamic address.) SNAP PAC Redundancy Option User’s Guide...
  • Page 22 (such as the built-in firewall in Windows) is disabled before you try to assign IP addresses. Firewalls in a router should not be a problem. 1. Make sure that the Opto 22 hardware is connected according to the instructions in Chapter 2: Connecting the Hardware, and that the PAC Control Pro software is installed on the PC.
  • Page 23 Does the PC have firewall software that blocks network broadcasts? If so, disable the software. 6. Click Select Device next to the MAC address of the controller. CAUTION: PAC Redundancy Manager lists ALL Opto 22 devices sending BootP or DHCP broadcasts. Assign an IP addresses only to the controller!
  • Page 24 8. When the IP address, subnet mask, and other fields are correct, click Assign IP Address. Progress is shown at the bottom of the screen. Progress 9. When all items user Progress are checked, click Done. 10. Repeat steps through for Controller 2. SNAP PAC Redundancy Option User’s Guide...

  • Page 25: Assigning An Ip Address To The Arbiter

    DHCP network, be aware that you must assign a fixed IP address to the PC’s network card (NIC) in order to communicate. 1. Make sure that the Opto 22 hardware is connected according to the instructions in Chapter 2: Connecting the Hardware, and that the PAC Control Pro software is installed on the PC.
  • Page 26 Does the PC have firewall software that blocks network broadcasts? If so, disable the software. 6. Click Select Device next to the MAC address of the arbiter. CAUTION: PAC Manager lists ALL Opto 22 devices sending BootP or DHCP broadcasts. Assign an IP addresses only to the arbiter!
  • Page 27 8. When the IP address, subnet mask, and other fields are correct, click Assign IP Address. Progress is shown at the bottom of the screen. Progress 9. When all items under Progress are checked, click Done. SNAP PAC Redundancy Option User’s Guide...

  • Page 28: Creating A Control Engine For Controller Redundancy

    Valid characters are letters, numbers, spaces, and most other characters except colons and square brackets. Spaces cannot be used as first or last characters. 6. Under System Type, select Redundant Controllers. New Settings options appear. SNAP PAC Redundancy Option User’s Guide...
  • Page 29 9. Click OK, and then exit PAC Terminal. 10. In PAC Redundancy Manager, under Redundant Control Engines, click Refresh. The control engine you created with redundant controllers appears under Redundant Control Engines. New redundant control engine SNAP PAC Redundancy Option User’s Guide...

  • Page 30: Commissioning The Controllers For Redundancy

    NOTE: The following instructions are for PAC Redundancy Manager. However, you can use PAC Terminal to commission the controllers for redundancy. 5. In PAC Redundancy Manager, under Tasks & Tools > Controller Management, click Commission for Redundancy. SNAP PAC Redundancy Option User’s Guide...
  • Page 31 The recommended settings for ENET 2 for Controller 2 are as follows: – Secondary IP Address: 172.22.22.3 – Subnet Mask: 255.255.255.240 9. When all the secondary IP address fields are correct, click Apply Settings. SNAP PAC Redundancy Option User’s Guide...

  • Page 32: Checking The System

    PAC is checked and the second PAC’s strategy is cleared; then the strategy from the first PAC is copied to the second PAC, and the second PAC is checked. 1. Under Task & Tools > System Management, simply click System Checkout. SNAP PAC Redundancy Option User’s Guide...
  • Page 33 If your system is properly configured, the results screen looks like this: Now you are ready to create a strategy designed for controller redundancy. See the next chapter, Chapter 4: Creating a Strategy with Controller Redundancy SNAP PAC Redundancy Option User’s Guide...
  • Page 34 CHECKING THE SYSTEM SNAP PAC Redundancy Option User’s Guide...

  • Page 35: Chapter 4: Creating A Strategy With Controller Redundancy

    Data generated by persistent/redundant variables that are replicated to an available backup controller whenever synchronization occurs. See Chapter 4: Creating a Strategy with Controller Redundancy. Redundant Control Engine A control engine configured for redundant controllers. See “Creating a Control Engine for Controller Redundancy” on page SNAP PAC Redundancy Option User’s Guide...

  • Page 36: Sequential Programming

    I/O, and it ends with a sync block. Transactional Chart A special PAC Control chart used to support persistent/redundant data with redundant controllers. A transactional chart always includes at least one sync block, which is used to define a transaction (see SNAP PAC Redundancy Option User’s Guide...

  • Page 37: Creating A Redundant Strategy

    PAC Redundancy Manager can be accessed within PAC Control for control engines configured for controller redundancy. You can also access PAC Redundancy Manager from the Start menu: select StartProgramsOpto 22PAC Project SoftwarePAC Redundancy Manager. For instructions on using Redundancy Manager, see “Step 2.
  • Page 38 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 available. For more information, see Chapter 4: Creating a Strategy with Controller Redundancy. Persistent/Redundant variable option SNAP PAC Redundancy Option User’s Guide...
  • Page 39 “Using Controller Redundancy – Debug Options” on page To enable the redundancy features in 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.

  • Page 40: Step 2. Adding A Redundant Control Engine To A Pac Control Strategy

    1. Make sure you have connected the hardware and configured a redundant system as described in the two previous chapters. 2. With a strategy open in PAC Control in Configure mode or Online mode, choose Configure  Control Engine. SNAP PAC Redundancy Option User’s Guide...

  • Page 41: Configuring An Existing Control Engine For Redundancy

    Define a control engine for your strategy as described in form 1700, the PAC Control User’s Guide. 2. Double-click your control engine on the Strategy Tree to open the Configure Control Engines dialog box. SNAP PAC Redundancy Option User’s Guide...
  • Page 42 NOTE: These are the addresses you configured previously for the controllers and arbiter. See “Assigning a Primary IP Address to ENET 1 on each Controller” on page 17 “Assigning an IP Address to the Arbiter” on page SNAP PAC Redundancy Option User’s Guide...

  • Page 43: Step 3. Configuring Persistent/Redundant Data

    When a redundant variable that resides in a transactional chart is changed, the value on that controller changes immediately, but it is not synchronized until the next sync block is encountered. When a redundant variable resides in a non-transactional chart (a chart without sync blocks), the SNAP PAC Redundancy Option User’s Guide...

  • Page 44: Persistent/Redundant Variables

    Using Variables and Commands in form 1700, the PAC Control User’s Guide. 1. Make sure that redundancy is enabled for the strategy. See page 2. With the strategy or subroutine open in Configure mode, choose Configure  Variables. SNAP PAC Redundancy Option User’s Guide...

  • Page 45: Step 4. Designing A Transactional Chart

    This section describes the basics of how to design a transactional chart, a special PAC Control chart that you must use if your strategy is used to support persistent/redundant data with redundant controllers. You create a transactional chart simply by adding sync blocks at strategic places in a PAC SNAP PAC Redundancy Option User’s Guide...
  • Page 46 If the active controller fails, the sync block also indicates to the backup controller what state the chart is in (running/stopped/paused) and where in the logic to begin. In this case, the backup controller takes over as the active controller. SNAP PAC Redundancy Option User’s Guide...

  • Page 47: Transaction Example

    Consider the following guidelines when designing a redundant control strategy: • Use persistent/redundant variables only as necessary. Because each additional persistent/redundant variable must be synchronized, too many persistent/redundant variables can increase system overhead and slow down the system. SNAP PAC Redundancy Option User’s Guide...

  • Page 48: Using Reads And Timers

    Each controller can read from that timer without requiring a sync block or synchronization to occur. However, stopping a timer requires a sync block to be encountered to stop the timer on both controllers. SNAP PAC Redundancy Option User’s Guide...

  • Page 49: What Causes Synchronization To Occur

    2. With the chart open and the strategy in Configure or Online mode, click the Sync block tool. Sync block tool 3. Move the mouse into the window, and notice an outline representing the block. SNAP PAC Redundancy Option User’s Guide...
  • Page 50 To use sync blocks in a chart’s logic, you’ll need to name the block, and connect it to other blocks in the chart. You can also change the size of the block, its color, and the font. For more information, see form 1700, the PAC Control User’s Guide. SNAP PAC Redundancy Option User’s Guide...

  • Page 51: Chapter 5: System Maintenance

    1. Make sure you have a fully configured redundant system, and your strategy is downloaded and running on your redundant system. For more information about downloading and running a strategy, see form 1700, the PAC Control User’s Guide. SNAP PAC Redundancy Option User’s Guide...

  • Page 52: Redundant System Status Messages

    The System Overview screen in PAC Redundancy Manager displays status messages about the state of the arbiter and the controllers. You can use this information to address problems with your system. For additional help, also see the next section, “Redundant System State Machine.” Status message SNAP PAC Redundancy Option User’s Guide...

  • Page 53: Using The Memory Map To Read Status Messages

    I/O unit’s memory map and putting it into a variable, you can display the status in PAC Display. The value returned indicates the redundant controller’s status, as follows: State Value (Decimal) Powerup SNAP PAC Redundancy Option User’s Guide...

  • Page 54: Using The Memory Map To Enter And Exit Maintenance Mode

    Messages appear in PAC Redundancy for each of the redundant controllers. For definitions of the status messages, see the previous section, “Redundant System Status Messages.” SNAP PAC Redundancy Option User’s Guide...
  • Page 55 Otherwise you might have two simultaneous active controllers. Because turning off power to a device that is doing a flash write may cause corruption of data in flash memory, writes to flash memory (such as configuration writes, strategy updates, and firmware updates) are disabled. SNAP PAC Redundancy Option User’s Guide...

  • Page 56: Changing An Ip Address On A Device

    2. In the Current IP Address text box, enter the current IP address for the device. 3. Click Read Current Settings to see the Subnet Mask, Gateway, and DNS Address. 4. Enter a new IP address or other setting as needed, and then click Apply Settings. SNAP PAC Redundancy Option User’s Guide...

  • Page 57: Installing New Firmware

    To generate a CDF file, open the strategy in PAC Control and select Compile > Compile Control Engine Download File. For more information, see form 1700, the PAC Control User’s Guide. 4. Under Firmware, browse to the firmware location and select the new firmware file. SNAP PAC Redundancy Option User’s Guide...

  • Page 58: Using The Controller Method

    Progress of the upload appears at the bottom of the window. If an error occurs, notice the on-screen message. Installing Firmware to the Arbiter NOTE: It is OK to install firmware to the arbiter while the system is running. SNAP PAC Redundancy Option User’s Guide...
  • Page 59 3. Under Arbiter Device, select Selected Arbiter. 4. Under Firmware, browse to the firmware location and select the new firmware file. 5. Scroll down to the bottom of the screen and click Update Firmware. SNAP PAC Redundancy Option User’s Guide...

  • Page 60: Managing Memory

    Erase Configuration from Flash: Erases the configuration stored in flash memory, which includes: – Clears error information in the status area (error code, transaction label, source address, error address). – Clears gains and offsets, counters (which are also deactivated), SNAP PAC Redundancy Option User’s Guide...
  • Page 61 To manage a strategy or configuration in memory: 1. In PAC Redundancy Manager, under Tasks & Tools > Controller Management, click Manage Memory. 2. Under Controller, select the controller to manage. 3. Under Memory Commands, select a command. SNAP PAC Redundancy Option User’s Guide...

  • Page 62: Using Advanced Functions

    A number of powerful advanced functions are provided which you can use to: • Troubleshoot the system • Use Maintenance mode to perform an operation not provided in PAC Redundancy Manager • Have the arbiter reset a controller • Directly control the power switch SNAP PAC Redundancy Option User’s Guide...
  • Page 63 Force Reset: Forces the arbiter to reset the controller. Hard Reset: Forces the arbiter to cycle the controller’s power. Redundant Power Switch State: Controls the redundant power switch. You can switch it on or off. SNAP PAC Redundancy Option User’s Guide...

  • Page 64: Using Controller Redundancy - Debug Options

    CAUTION: In order to avoid having two active controllers at the same time or unpredictable behavior from your system, make sure that the other controller is off. Debug Backup Controller: Use this option only if you want to debug the current qualified backup controller. No downloads are allowed. SNAP PAC Redundancy Option User’s Guide...

  • Page 65: Arbiter Status Leds And Blink Codes

    I/O units, or not qualified CTR1 Orange = backup qualified Green-blinking = becoming active, or active but cannot communi- cate with one or more configured I/O units Green = active nominal SNAP PAC Redundancy Option User’s Guide...

  • Page 66: Resetting The Arbiter

    STAT LED blinking orange, rapidly and continuously. Hardware test mode erases all files in RAM and flash memory and resets the IP address. If SNAP PAC Redundancy Option User’s Guide...
  • Page 67 7 times quickly. This is a diagnostic mode that you don’t need to access unless you are troubleshooting a problem with Opto 22 Product Support. If your arbiter restarts in failsafe bootloader mode, cycle power; the result will be same as the simple restart described above.
  • Page 68 RESETTING THE ARBITER SNAP PAC Redundancy Option User’s Guide...

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