SBC PCD3.M6880 User Manual
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SBC PCD3.M6880 User Manual

Standby system redundant automation solutions
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User Manual
Saia PCD
Standby System
®
redundant automation solutions
Document 27-645 │ Edition ENG02 │ 2017-04-26

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Summary of Contents for SBC PCD3.M6880

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

  • Page 2: Table Of Contents

    Terminology ................... 1-3 Designing the System ................1-5 Order details ..................1-6 PCD3.M6880 Standby Controller ............1-7 1.5.1 Architecture of the PCD3.M6880 ............1-7 1.5.2 PCD3.M6880 Technical Data ..............1-8 1.5.3 Switchover Criteria ................1-9 PCD3.T668 Standby RIO ..............1-10 1.6.1...
  • Page 3 Contents Saia-Burgess Controls AG PCD2.M4x60 Technical Information Data Synchronization and Switchover (Synchronous) ......4-1 Data Synchronization and Switchover (Asynchronous) ......4-1 LED States .................... 4-1 State Machine ..................4-2 Troubleshooting ..................4-2 Annex Icons ...................... A-1 Instructions for connecting Saia-PCD controllers to the internet ..

  • Page 4: Document History

    Contents Saia-Burgess Controls AG PCD2.M4x60 Document History Version Changes Published Comments ENG01 2015-11-27 2015-11-27 First edition 2016-03-11 2016-03-16 PCD3.Fxxx --> 26-857 2017-04-03 2017-04-03 new footer ENG02 2017-04-26 2017-04-26 Ch3.1 - more possible failures listed Trademarks Saia PCD is a registered trademark of Saia-Burgess Controls AG. ®...

  • Page 5: Standby System Overview

    Saia-Burgess Controls AG Introduction Standby System Overview Introduction The PCD3.M6880 Standby Controllers are for creating redundant automation solutions, to ensure the uninterrupted operation of systems and processes. Standby (redundant automation) systems from SBC have the following char- acteristics: ■ Based on the modular and robust PCD3 family, using standard modules.
  • Page 6 Smart RIOs PCD3.T668 Process I/O Process I/O Typical layout of a redundancy system with two PCD3.M6880 Standby devices and PCD3.T668 Ethernet Smart RIOs. User Manual Standby System │ Document 27-645 │ Edition ENG  0 2 │ 2017-04-26...

  • Page 7: Terminology

    Terminology The following definitions will provide a better understanding of the proper- ties and operating principles: Standby Controller The PCD3.M6880 controller which supports the standby feature. Primary PCD The PCD which becomes the active device by default when the system is powered up, depending on the configuration.
  • Page 8 Standby System Overview Saia-Burgess Controls AG Terminology Redundant control solutions are created using two PCD3.M6880 Standby Controllers. The input/outputs (process signals) are connected and controlled via PCD3.T668 Ethernet smart RIOs. The RIO stations are connected to both controllers via an Ethernet connection. This means there is no need to have duplicate inputs, outputs, sensors and actuators.

  • Page 9: Designing The System

    SCADA 2 SCADA 1 SCADA 2 SCADA-System SCADA-System Ethernet Ethernet Primary Secondary Primary Secondary Standby Controller Standby Controller PCD3.M6880 PCD3.M6880 Ethernet Network redundancy with fiber optical ring Smart RIOs Smart RIOs PCD3.T668 PCD3.T668 Process I/O Process I/O Process I/O Process I/O...

  • Page 10: Order Details

    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 User Manual Standby System │ Document 27-645 │ Edition ENG  0 2 │ 2017-04-26...

  • Page 11: Pcd3.M6880 Standby Controller

    PCD. Depending on requirements, the user programs 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.

  • Page 12: Pcd3.M6880 Technical Data

    Standby System Overview Saia-Burgess Controls AG PCD3.M6880 Standby Controller 1.5.2 PCD3.M6880 Technical Data PCD3.M6880 Property/function Main CPU0 Redundant CPU1 Number of inputs/outputs 1023 –– or I/O-module slots –– I/O expansion connection for PCD3.C module holder –– Processing time [µs] bit operation 0.1…0.8 µs...

  • Page 13: Switchover Criteria

    Standby System Overview Saia-Burgess Controls AG PCD3.M6880 Standby Controller 1.5.3 Switchover Criteria Each of the Standby PCDs (CPU1) sends a „Keep Alive“ telegram to its partner for supervision. The STANDBY PCD switches to ACTIVE when: ■ No Keep Alive telegram has been received within the „Keep alive timeout“...

  • Page 14: Pcd3.T668 Standby Rio

    PCD3.T668 Standby RIO 1.6.1 Architecture of the PCD3.T668 The PCD3.T668 remote I/Os are exclusively for use with the PCD3.M6880 Standby Controllers. With the exception of the redundancy function, they support the same properties/functions as the PCD3.T666 remote I/O station. The PCD.

  • Page 15: Technical Data

    Standby System Overview Saia-Burgess Controls AG PCD3.T668 Standby RIO 1.6.2 Technical Data Property PCD3.T668 Number of inputs/outputs 64 in base unit, extensible to 256 I/O-module slots 4 in base unit, extensible to 16 I/O-modules supported PCD3.Exxx, PCD3.Axxx, PCD3.Bxxx, PCD3.Wxxx Max. number of RIO stations Protocol for data transfer Ether-S-IO Ethernet connection...

  • Page 16: Configuration And Programming

    Diagnostic Saia-Burgess Controls AG Creating a Standby System Project in PG5 Configuration and Programming Creating a Standby System Project in PG5 The Saia PG5 has many features to help you create a standby system project. It ® will create the three standby devices for you (primary, secondary and redundant), and creates the symbol files for defining the data to be exchanged between the CPUs.
  • Page 17 Diagnostic Saia-Burgess Controls AG Creating a Standby System Project in PG5 2. Add the Primary standby device The “New Device” dialog box will 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”...
  • Page 18 Diagnostic Saia-Burgess Controls AG Creating a Standby System Project in PG5 3. Configure the standby system When OK is pressed to create the device, Project Manager creates the primary device, then displays the Standby System Configuration dialog box with the default configuration: By default, a single symbol file is used to define the media for transfer between CPU0 and CPU1 on the Primary and Secondary devices.
  • Page 19 Diagnostic Saia-Burgess Controls AG Creating a Standby System Project in PG5 defaults is good for starting the project. See the Standby System Configuration dialog box for more details. Renaming or deleting devices and files If you use Project Manager to rename or delete one of the standby devices or symbol files, then you must open the ‘Standby Configuration’...

  • Page 20: Project Manager View

    Diagnostic Saia-Burgess Controls AG PG5 Project Manager View PG5 Project Manager View The three devices and their symbol files are shown in the PG5 Project Manager’s “Project Tree”. If the Redundant device connects to programmed RIOs, you will also see the RIOs in the Project Tree. Each device defines its own symbol file(s), see Media Exchange.

  • Page 21: Process Data Synchronization

    Diagnostic Saia-Burgess Controls AG Process Data Synchronization Process Data Synchronization All media used by the CPU1 Redundant program are synchronized between CPU1 of the Active and the CPU1 of the Standby device. The data can be synchronized cyclically (e.g. at the end of every cycle, all the data are transferred and the next cycle beings only after all data has been sent), or it can be sent asynchronously without slowing the program cycles.
  • Page 22 Diagnostic Saia-Burgess Controls AG Process Data Synchronization Indexed Addressing The media addresses of the synchronization data are taken from the addresses actually 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’...

  • Page 23: Media Exchange

    Diagnostic Saia-Burgess Controls AG Media Exchange Media Exchange To communicate between CPU0 and CPU1 on each device, and between the programs on the Primary and Secondary devices, media values can be transferred cyclically between each CPU. Special symbol files are used to define the media to be transferred between CPU0 and CPU1 of the Primary and Secondary devices and the media to be transferred between the CPU1s of the Primary and Secondary devices.
  • Page 24 System overview Saia-Burgess Controls AG Media Exchange For the STANDBY CPU0 the process is almost the same: 1a. CPU0 of the STANDBY device modifies the media values of symbols defined in “RedSymbols.sy5”. 2a. The modified media values are transferred through CPU1 to the corresponding media in CPU1 of the ACTIVE device.
  • Page 25 Diagnostic Saia-Burgess Controls AG Media Exchange NOTES Indexed Addressing The media addresses of the synchronization data are taken from the addresses actually 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’...

  • Page 26: Configuration

    2.5.1 Standby System Configuration dialog box If the project contains 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.
  • Page 27 Secondary Device (CPU0) This is CPU0 of the second PCD3.M6880. Secondary device name The name of the PCD3.M6880 Secondary device in the PG5. The default is “2-Secondary”. Press the “...” browse button to select an existing PCD3.M6880 device. 2-12...
  • Page 28 “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 OK is pressed, Project Manager checks for the presence of the Primary, Secondary and Redundant devices and symbol files.

  • Page 29: Redundant Device Configuration

    Diagnostic Saia-Burgess Controls AG Configuration Validation Project Manager will validate the standby system configuration when the dialog box is closed, when certain changes are made, and before a build is done. If any errors are found they are reported in the Messages window, and they should be corrected before continuing.
  • Page 30 Diagnostic Saia-Burgess Controls AG Configuration time, depending on the amount of data and the complexity of the program. This means that the standby CPU’s data may be some cycles behind the active CPU. “Program Cycle” will transfer the data on every program cycle and wait until the data is sent.

  • Page 31: Creating A Default Rio Configuration

    The device does not exist in the project. If the name is incorrect, rename it or change its name in the Redundancy Configuration. If the device 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’...
  • Page 32 Diagnostic Saia-Burgess Controls AG Configuration file: <file_name> Error 7003: Secondary device does not reference Redundant device’s sym- bol file: <file_path> Error 7004: Redundant device does not reference Primary device’s symbol file: <file_path> Error 7004: Redundant device does not reference Secondary device’s sym- bol file: <file_path>...
  • Page 33 Diagnostic Saia-Burgess Controls AG Configuration is hard-wired in the firmware. Communications will not work unless the station number is 253. Error 7012: Primary and Secondary devices have the same S-Bus station number The Primary and Secondary devices must have different S-Bus station num- bers.

  • Page 34: Downloading The Device Configuration

    ‘USB Serial Number’ list and choose the correct device. The USB serial number is created from the device type and the device’s PCD serial number, e.g. PCD3.M6880 8A56C170000. If using Ethernet, enter the IP addresses you used in the device configuration for the 1-Primary and 2-Secondary devices.

  • Page 35: Programming

    Programming The programs “1-Primary” and “2-Secondary” are for CPU0 of the dual-processor PCD3.M6880. These programs are often the same, but they can be different in each device. Unlike the Redundant device, the programs in these devices can do communications and direct I/O accesses. See CPU0 Control Program.
  • Page 36 Diagnostic Saia-Burgess Controls AG Programming program in both the Primary and the Secondary devices, then the symbol names must also be the same. This means that you cannot use the “Separate symbol files” option because there will be “multi-defined symbol” errors in CPU1 because the same symbol names must be used in ToRedSymbolsPrimary.sy5 and ToRedS- ymbolsSecondary.sy5.
  • Page 37 Diagnostic Saia-Burgess Controls AG Programming Referencing the program files of another device Alternatively, you can create the file in the Program Files branch of the Primary device, and reference them from the Secondary device (or vice-versa). Create the program files in the Primary device, then right-click on the Secondary device’s Program Files branch and select the “Add Files..”...
  • Page 38 Diagnostic Saia-Burgess Controls AG Programming 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. 2-23 User Manual Standby System │ Document 27-645 │ Edition ENG  0 2 │ 2017-04-26...

  • Page 39: Cpu1 Redundant Program

    Diagnostic Saia-Burgess Controls AG Programming 2.6.2 CPU1 Redundant Program CPU1 of the Active device runs the Redundant program, and its process image must be synchronized with the process image of CPU1 in the Standby device. This means that no features that are asynchronous, use non-process data or com- munications stacks can be used on CPU1.

  • Page 40: Going Online To Active Cpu1

    Watch Window for CPU1, it will use the current Online Settings - it will not try to find the Active CPU1 even if the “PCD3.M6880 ACTIVE CPU1” channel is select- ed. To connect to the Active CPU1, you should first do a ‘Go Online’ for CPU1 with the “PCD3.M6880 ACTIVE CPU1”...

  • Page 41: Switchover Xob 31

    Diagnostic Saia-Burgess Controls AG Programming Forcing a switch-over using S-Bug To test the switch-over, you can connect to the Active CPU1 with S-Bug, do a “Stop” command, then “Instruction HALT”. This Halts the Active CPU1 and the Standby CPU becomes Active. Note that the Standby CPU does not become Ac- tive when the Active CPU goes into Stop - this is because you would not be able to debug a program on the Active CPU1 without it causing a switch-over.

  • Page 42: Download Programs To Standby System Dialog Box

    2.6.5 Download Programs to Standby System dialog box A standby system project consists of two PCD3.M6880 devices (the Primary and the Secondary devices), and each of these devices contains two CPUs. This means that programs must be downloaded into four separate CPUs. To make this easier, all four programs can be downloaded in a single step by using the “Down-...
  • Page 43 Diagnostic Saia-Burgess Controls AG Programming Program Info... buttons Displays the “Program Information” dialog box, which shows the details of the PG5 program and the program within the connected PCD. Use this to see more details if the Program Status is not “up-todate”. Download...
  • Page 44 Diagnostic Saia-Burgess Controls AG Programming Error Messages These are the error messages and notifications that may be displayed by this dialog box, in alphabetical order. The message may also contain the device name and the expected and actual values. Cannot download to Primary/Secondary CPU x, it is offline or using reduced protocol If the PCD is password protected, enter the password when it is asked, before connecting to the PCD.
  • Page 45 Diagnostic Saia-Burgess Controls AG Programming Device’s Serial Number not defined in ‘Downloader Options’ It is a good idea to check the destination PCD’s serial number, to be extra-sure that you are downloading the program into the correct PCD, especially if it is one of many on a network.
  • Page 46 IP configuration is correct and has been downloaded. Check for another error message, such as “Invalid Primary CPU 1 IP address”. Wrong PCD type The connected PCD is not a PCD3.M6880 or PCD3.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...

  • Page 47: Diagnostics

    Technical Imformation Saia-Burgess Controls AG Halt and History Messages Diagnostics Halt and History Messages If a CPU halts due to a standby system error, a message is placed in the Halt Rea- son Register and an entry is made in the History log. Message HALT Meaning...

  • Page 48: Diagnostic Tags

    Technical Imformation Saia-Burgess Controls AG Diagnostic Tags Diagnostic Tags There are some diagnostic tags which show the current state of the redundancy system. The section name is [SYS-Redundancy]. These diagnostic tags are also present in the redundancy CPU1. Message CFG Access Def. Min/ Description Remarks...

  • Page 49: Diagnostic Flags

    Technical Imformation Saia-Burgess Controls AG Diagnostic Flags | Diagnostic Registers Diagnostic Flags An array of 8 flags is used for diagnostic flags on both CPUs. System symbols are assigned, which are shown on the “System” tab of the Symbol Editor. The base flag symbol name is: S.STANDBY.DiagFlagBase Offset System Symbol Name...

  • Page 50: Ether-Sio Diagnostics Extension

    Technical Imformation Saia-Burgess Controls AG Ether-SIO Diagnostics Extension Ether-SIO Diagnostics Extension The diagnostics flags of the PCD3.T668 are extended to show the status of the two managers. These symbols are shown on the “All Publics” tab of the RIO pro- gram’s Symbol Editor, in the group RIO: Offset System Symbol Name...

  • Page 51: Technical Information

    Data Synchronization and Switchover (Synchronous) Data Synchronization: Program Cycle Data Synchronization and Switchover (Asynchronous) Data Synchronization: Program Cycle LED States The RUN and Error LEDs on the PCD3.M6880 show the standby status: Standby State RUN LED State Error LED State IDLE...

  • Page 52: State Machine

    System overview Saia-Burgess Controls AG State Machine | troubleshooting State Machine Troubleshooting Problem Cause Remedy The Active PCD is in RUN but the The redundancy configuration is Download the same configuration Standby PCD is in HALT. not the same on both PCD’s. to both PCD’s.

  • Page 53: A Annex

    VPN connections. For more information, please refer to our support site: www.sbc-support.com/security User Manual Standby System │ Document 27-645 │ Edition ENG  0 2 │ 2017-04-26...

  • Page 54: Contact

    Email support: ......support@saia-pcd.com upportsite: ......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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