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Emerson PACSystems RX3i User Manual

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USER MANUAL
GFK-2409B
Oct 2019
PACSystems
TM
RX3i
MAX-ON HOT STANDBY REDUNDACY
USER MANUAL

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Summary of Contents for Emerson PACSystems RX3i

  • Page 1 USER MANUAL GFK-2409B Oct 2019 PACSystems RX3i MAX-ON HOT STANDBY REDUNDACY USER MANUAL...

  • Page 2: Table Of Contents

    User Manual Contents GFK-2409B Oct 2019 Contents Chapter 1: Introduction ............1 Installing Max-ON RX3i Software ................. 2 1.1.1 System Requirements ................2 1.1.2 To Install Max-ON RX3i Software ............... 2 1.1.3 Uninstalling Max-ON RX3i Software ............2 1.1.4 Max-ON RX3i Component Installation ............3 Chapter 2: System Overview ...........
  • Page 3 User Manual Contents GFK-2409B Oct 2019 Chapter 7: Configuring the I/O Devices ......... 86 Configuring the Ethernet I/O Devices ..............86 Configuring the Genius I/O Devices ..............87 Chapter 8: Diagnostic Tools ..........100 Step 1 - Create a Max-ON RX3i Diagnostic Tool View Project ......100 Step 2 –...
  • Page 4 This document is intended for trained personnel familiar with the Emerson products referenced herein. Emerson may have patents or pending patent applications covering subject matter in this document. The furnishing of this document does not provide any license whatsoever to any of these patents.

  • Page 5: Chapter 1: Introduction

    Create a Hot Standby system that operates using a combination of Emerson Genius™ I/O, Field Control™, Series 90™-30 remote Genius drops, and Genius VersaMax™ I/O, as well as Series 90-30 and PACSystems RX3i Ethernet NIUs. • Provide data synchronization using an Ethernet LAN.

  • Page 6: Installing Max-On Rx3I Software

    Add/Remove Programs option on the Windows Control Panel or from the Windows Start Menu. If the computer has other Emerson software products installed, Max-ON RX3i Software can be uninstalled without removing any files needed by those applications. To uninstall Max- ON RX3i Software, do the following: 1.

  • Page 7: Max-On Rx3I Component Installation

    Max-ON RX3i Component Installation The default settings for the Max-ON RX3i software installation places the Max-ON RX3i Software and the associated project components in the Emerson directory. The Max-ON RX3i components are installed in the tree structure as shown below: Figure 1: The Max-ON RX3i Configuration Utility is located in Max-ON RX3i Tools directory.
  • Page 8 User Manual Chapter 1 GFK-2409B Oct 2019 Adding the Max-ON RX3i Hot Standby Redundancy Application Project to PAC Machine Edition The default Max-ON RX3i LD project is added to the Machine Edition project Navigator by using the File > Restore Project…menu item. Select the Project Navigator window making certain that there is no project open at this time.
  • Page 9 User Manual Chapter 1 GFK-2409B Oct 2019 Select the Max-ON RX3i LD Project vx_yy.zip file. Figure 5: When you click on Open, a new project will be added to the PAC Navigator window. Now you may give this new Project a descriptive project name. You may also use this project to create a Machine Edition project template that can be used as a starting point for future Max-ON RX3i projects.
  • Page 10 User Manual Chapter 1 GFK-2409B Oct 2019 • PLC_COMMON_CODE – This target contains the core logic for the Max-ON RX3i redundancy application. You must add your application logic starting in the rung that follows the call to the core Max-ON RX3i logic (hbr_000). The logic from this target will be downloaded to both PLC A and PLC B.

  • Page 11: Chapter 2: System Overview

    Ethernet drops (Series 90-30 ENIU or PACSystems RX3i ENIU); or Genius drops (Genius I/O, Field Control I/O, VersaMax I/O, or Remote I/O drops based upon Series 90-30 I/O). The example below shows the Max-ON RX3i controllers connected to a single Ethernet I/O LAN.
  • Page 12 Up to 3 simplex Ethernet busses, or one dual Ethernet bus Synchronizing LANs One or two Ethernet LANs CPU Model IC695CMU310 I/O Families Ethernet: Series 90-30 Ethernet NIU or PACSystems RX3i Ethernet NIU Genius: Genius Block, Field Control, VersaMax, Remote 90-30 Drop System Overview...

  • Page 13: Software Components

    User Manual Chapter 2 GFK-2409B Oct 2019 Software Components Max-ON RX3i software consists of several components, some of which execute in the Hot Standby Controllers, and some of which execute in your programming workstation. A base Logic Developer PLC Project provides the basic template for the Logic of the Redundant System.

  • Page 14: Hot Standby Redundancy Operation

    User Manual Chapter 2 GFK-2409B Oct 2019 Hot Standby Redundancy Operation During each controller scan, the Max-ON RX3i redundancy drivers are solved first, and then your application logic is solved. The Max-ON RX3i redundancy drivers handle the following functions: • Determine Mastership –...

  • Page 15: Synchronized Data Transfers

    User Manual Chapter 2 GFK-2409B Oct 2019 assumes that each device has been configured for either BSM present or for long timeout.) Then the output device will begin using output data from the other GBC. Synchronized Data Transfers Data may be synchronized from the Master to the Backup on a continuous basis in order to assure that the Backup controller’s data is always in sync with the Master’s.

  • Page 16: Selecting The I/O

    Max-ON RX3i systems may be implemented using any combination of the following I/O: Ethernet NIUs Ethernet NIUs are remote I/O drops that as based on standard 90-30 or PACSystems RX3i hardware. These remote drops communicate to the redundant controllers using Ethernet Global Data. These NIUs are configured using Logic Developer PLC.

  • Page 17: Demo Mode Operation

    User Manual Chapter 2 GFK-2409B Oct 2019 Genius Third Party In some cases, third party devices may be used on the LAN as well. These devices must comply with the Genius I/O specification relating to Controller Redundancy. With a Max-ON RX3i system, you may select I/O devices based upon functionality, cost, physical design, items carried in spare parts inventory, or personnel expertise.

  • Page 18: Chapter 3: Building A Max-On Rx3I Hot Standby Application

    User Manual Chapter 3 GFK-2409B Oct 2019 Chapter 3: Building a Max-ON RX3i Hot Standby Application Max-ON RX3i Project Max-ON RX3i encapsulates your entire application within a single Machine Edition Project. Using a generic Max-ON RX3i Project, you can create a new Max-ON RX3i Redundancy project.
  • Page 19 User Manual Chapter 3 GFK-2409B Oct 2019 Step 2 - Create a New Max-ON RX3i Project In PAC Logic Developer PLC: 1. Create a new project based on the Generic Max-ON RX3i Project. The redundant ladder project is added to the Machine Edition project Navigator by using the File > Restore Project menu item.
  • Page 20 User Manual Chapter 3 GFK-2409B Oct 2019 When you click on Open, a new project will be added to the PAC Navigator window. Figure 16: 4. Give your project a descriptive name in the Machine Edition Navigator. 5. Enter Project Setting information by launching the Project Settings dialog in the Max-ON RX3i Configuration Utility.
  • Page 21 User Manual Chapter 3 GFK-2409B Oct 2019 For CPU B: 1. Open the Hardware Configuration for PLC_B_HW target in the Max-ON RX3i Project. 2. Configure the PLC hardware for PLC B. • CPU Memory • CPU SNP ID • Genius Bus Controllers •...
  • Page 22 User Manual Chapter 3 GFK-2409B Oct 2019 Step 5 - Configure the I/O Devices Ethernet NIUs If you are using Ethernet NIUs, then you will need to create Ethernet NIU targets, configure the I/O in the remote drop, and then download the ENIU information to the remote drop using Logic Developer PLC.
  • Page 23 User Manual Chapter 3 GFK-2409B Oct 2019 With the I/O operating, place CPU A in STOP mode and CPU B in RUN mode. • Verify that the system input devices return real-time values properly. • Verify that system output devices may be controlled from the Output Reference Tables.
  • Page 24 User Manual Chapter 3 GFK-2409B Oct 2019 • Disable your application code and troubleshoot the Max-ON functionality. Check to make certain that synchronized data items transfer properly. Check to make certain that the Hot Standby CPUs will exchange mastership properly. Building a Max-ON RX3i Hot Standby Application...

  • Page 25: Chapter 4: The Max-On Rx3I Configuration Utility

    User Manual Chapter 4 GFK-2409B Oct 2019 Chapter 4: The Max-ON RX3i Configuration Utility The Max-ON RX3i Configuration Utility is used to create or edit the operating parameters used by the Max-ON RX3i redundancy drivers. These parameters specify such things as, bus topologies, I/O addresses, and definitions for the ranges of synchronized data transfers.
  • Page 26 User Manual Chapter 4 GFK-2409B Oct 2019 The diagram below illustrates how the Max-ON RX3i Project is organized: Figure 18: When creating a Max-ON RX3i Project, the best approach is to start with the generic project that is supplied with the Max-ON RX3i software. This assures that all the basic components of the Max-ON RX3i redundant application are included in the project.
  • Page 27 User Manual Chapter 4 GFK-2409B Oct 2019 2. Using the File menu, click on the Restore Project. menu. Figure 20: 3. Navigate to the PAC Components directory where the Max-ON RX3i Tools software has been installed, then to the Redundant LD directory. Make certain that the selection for Files of Type in the Restore dialog has been set to PAC Machine Edition (*.zip).
  • Page 28 User Manual Chapter 4 GFK-2409B Oct 2019 Figure 22: 6. Give your project a descriptive name in the Machine Edition Navigator. Launching the Max-ON RX3i Configuration Utility The Max-ON RX3i Configuration Utility is launched from the Max-ON RX3i Machine Edition Project.
  • Page 29 User Manual Chapter 4 GFK-2409B Oct 2019 Figure 24: 4. Double-click on Documentation Files. This will launch Windows Explorer for this directory 5. Click on the Max-ON Project directory to display contents. The Explorer window will be like what is shown below. Figure 25: 6.

  • Page 30: Working With The Max-On Rx3I Configuration Utility

    User Manual Chapter 4 GFK-2409B Oct 2019 Working with the Max-ON RX3i Configuration Utility Now that you have created a Max-ON RX3i Project and launched the Max-ON RX3i Configuration Utility, you can set the parameters of the redundant system. When the Max-ON RX3i Configuration Utility is launched it will display the following: Figure 26: As you can see from the Project Navigator, the utility allows you to specify the following...
  • Page 31 User Manual Chapter 4 GFK-2409B Oct 2019 Figure 27: Settings By selecting the Settings item in the Project tree, the Max-ON RX3i System Parameters settings may be displayed and modified. These parameters are defined as follows. Figure 28: Fast Offline Detection - Enabling this option directs the CPUs to detect an offline condition within one CPU scan.
  • Page 32 User Manual Chapter 4 GFK-2409B Oct 2019 Synchronization data from the %M, %Q, %AQ, and %R reference tables may be transferred from the Master CPU to the Backup CPU for the redundant system to be synchronized. By selecting the Sync Data item in the Project tree, the Max-ON RX3i Sync Data settings may be displayed and modified.
  • Page 33 User Manual Chapter 4 GFK-2409B Oct 2019 Figure 31: Maximum Sync Data For each Synchronized Data type, the system will sum the lengths in each configured group to arrive at a total amount for that data type. The total must not exceed the size listed in the table below: Registers Discrete Outputs...
  • Page 34 User Manual Chapter 4 GFK-2409B Oct 2019 Figure 32: To edit this information, double-click on the LAN Interface Modules item in the project tree or select the Module > Properties… menu item. The Ethernet Modules configuration dialog is now displayed and the information about them can be entered. Figure 33: Configuring Dual Sync Networks If you want to use a dual Ethernet Sync Networks, then you must use two ETM001 modules...
  • Page 35 User Manual Chapter 4 GFK-2409B Oct 2019 Networks node in the project tree. Then select the Networks > Redundancy > Add Secondary Network menu item. Figure 34: Now the Secondary Network will be added to the system, and parameters may be configured.
  • Page 36 User Manual Chapter 4 GFK-2409B Oct 2019 Genius Busses By selecting the Genius Busses item in the Project tree, the Max-ON RX3i Genius busses may be displayed and their settings may be modified. By default, no Genius busses are defined, so you must configure the bus definitions to match your hardware configuration.
  • Page 37 User Manual Chapter 4 GFK-2409B Oct 2019 3. After the Genius bus has been created, it is added to the Project tree and now Genius devices may be added to this bus. Figure 38: 4. Double-click on the Primary Bus Controller item in order to configure parameters, or select the Busses >...
  • Page 38 User Manual Chapter 4 GFK-2409B Oct 2019 Adding a Secondary Genius Bus To add a Secondary Genius Bus to an Existing Genius Bus Select the Genius Bus in the Project tree, and then select the Busses > Redundancy… > Add Secondary Bus.. menu item to add a Secondary Genius Bus. Figure 40: A Secondary Genius Bus Controller is added to the Project tree.

  • Page 39: Adding Genius I/O Devices

    User Manual Chapter 4 GFK-2409B Oct 2019 Double-click on the Secondary Bus Controller in order to configure it’s parameters or select the Busses > Properties… or Module > Properties… menus. Enter the module’s location in the RX3i main rack and it’s status address. A suggested practice is to address Genius bus controllers at high addresses.
  • Page 40 User Manual Chapter 4 GFK-2409B Oct 2019 1. Select an SBA for the new Genius device by clicking on the gray button to the left of the SBA number. A “ ” will be placed on the button to indicate it is selection. 2.
  • Page 41 User Manual Chapter 4 GFK-2409B Oct 2019 4. If the I/O Family is Genius, then select the I/O Type for the I/O device. Click in the cell labeled I/O Type. A dropdown list will appear: Figure 46: 5. Select the I/O Type for the device, using the drop-down list selections. If your I/O device does not match with any of the selections, then select Generic.
  • Page 42 User Manual Chapter 4 GFK-2409B Oct 2019 Figure 48: 8. Edit the device properties for both the Primary and Secondary busses. 9. Click Apply and Ok to complete the changes or Cancel to leave without making any changes. Editing Genius, I/O Devices 1.
  • Page 43 User Manual Chapter 4 GFK-2409B Oct 2019 4. Edit the device properties 5. Click Apply and Ok to complete the changes or Cancel to leave without making any changes. Deleting Genius, I/O Devices 1. To delete a Genius device, select the Genius I/O bus from the Project tree for the item to be deleted.
  • Page 44 User Manual Chapter 4 GFK-2409B Oct 2019 Discrete Inputs – Secondary Bus When a dual bus is used, there must be an alternate location for the Genius discrete inputs to report their status. The alternate location is the reference area in which the inputs will appear while they are connected to the Secondary Genius I/O bus.
  • Page 45 User Manual Chapter 4 GFK-2409B Oct 2019 Configuring Genius Analog Inputs The Genius Device dialog allows you to configure how the Max-ON RX3i redundancy driver will process Genius analog inputs. The analog inputs may be configured on a per circuit basis.
  • Page 46 RU Upper value, then an alarm will be generated for the analog circuit. Notes: Many of the Emerson analog input devices are capable of performing scaling independently. It is better to use the built-in capabilities of the devices. This will reduce the CPU scan time by eliminating the extra processing associated with the scaling function.
  • Page 47 User Manual Chapter 4 GFK-2409B Oct 2019 Figure 53: Configuring the Secondary Address On dual bus systems, discrete and analog inputs are mapped from the Primary bus controller’s buffers into the normal input reference tables. Inputs from the Secondary bus controller are placed into an alternate area and then the Max- ON RX3i redundancy driver remaps the alternate states into the table area used by the Primary.

  • Page 48: Project Information

    User Manual Chapter 4 GFK-2409B Oct 2019 Secondary Bus References The configuration utility will display the configuration options for the Secondary bus references automatically. Please use the configuration information displayed in the text window to obtain the information that is needed to configure the Secondary bus controllers for discrete and analog inputs.

  • Page 49: User Defined Alarms

    User Manual Chapter 4 GFK-2409B Oct 2019 4.2.3 User Defined Alarms The user may post user defined faults from within the application. However, before the Max- ON RX3i Diagnostics can display the user alarms, they must be configured. Note: User Defined Alarms are not available in the current version of the Max-ON RX3i Diagnostics. Adding a User Alarm 1.
  • Page 50 User Manual Chapter 4 GFK-2409B Oct 2019 4. Enter any additional alarms. Figure 57: 5. Save your Max-ON RX3i Configuration, update the cfg_dat C Block in the Max-ON Project. 6. Download the new Max-ON RX3i Configuration to the CPUs. Deleting a User Alarm 1.

  • Page 51: Chapter 5: Programming Considerations

    User Manual Chapter 5 GFK-2409B Oct 2019 Chapter 5: Programming Considerations This chapter provides additional information on programming considerations and system resources for the Max-ON RX3i product. In many cases, Max-ON RX3i System Variables have been predefined to use in application logic in order to interact with the Max-ON RX3i redundancy driver.
  • Page 52 User Manual Chapter 5 GFK-2409B Oct 2019 Variable Name Reference Description ID_A %M01017 ID Flag for CPU A ID_B %M01018 ID Flag for CPU B CPU_RUN %M01019 CPU is in RUN Mode MASTER %M01020 Master Flag SYNC_OK %M01021 All Data has been Synchronized %M01022 –...
  • Page 53 User Manual Chapter 5 GFK-2409B Oct 2019 Local Status Flags – Instantaneous The following status flags represent the instantaneous (not latched) state corresponding to the associated descriptors. Variable Reference Description Name AUTH_ALM %M00961 Authorization Alarm REM_OFF %M00962 Remote CPU Offline PROG_CHG %M00963 Program Changed...
  • Page 54 %M00993 Authorization Alarm – This alarm bit indicates that the corresponding PLC is operating in DEMO mode on a standard PACSystems RX3i CPU (IC695CPU310). When the CPU is replaced by a Max-ON cpu (IC695CMU310), this flag may be reset using the RST_LOC or RST_ALL variables.
  • Page 55 User Manual Chapter 5 GFK-2409B Oct 2019 Local Status Flags – Latched (cont.) Reference Description %M01001 Power Up %M01002 Program Restart %M01003 Max-ON Alarm (Fault) Present %M01004 Max-ON Alarm (Fault) Table Full %M01005 Config Fault %M01006 Reserved – %M01008 %M01001 Power Up –...
  • Page 56 User Manual Chapter 5 GFK-2409B Oct 2019 %M00930 Remote Forces (Overrides) Present – There is at least one force (override) present in the remote, same as #OVR_PRE (%S0011) in the remote. %M00931 Remote PLC Low Battery – Same as #PLC_BAT (%S0014) in the remote. %M00932 Remote Config Mismatch –...
  • Page 57 User Manual Chapter 5 GFK-2409B Oct 2019 %M00960 System Command Flags Operation of the system may be influenced by interfacing to the Max-ON RX3i command flags. They may be accessed within application logic, and in some instances by an HMI. Variable Name Reference Description...
  • Page 58 User Manual Chapter 5 GFK-2409B Oct 2019 Mastership Modes You may specify the Mastership mode of operation for the Hot Standby CPUs. This may be accomplished by setting the states of the System Command Flags, SEL_A (%M01009) and SEL_B (%M01010). Both CPUs must have the states set identically in order to function properly.
  • Page 59 User Manual Chapter 5 GFK-2409B Oct 2019 Figure 59: Setting a Preferred Master You may set a permanent, Preferred Master. In this mode, if the corresponding CPU fails (or is placed in STOP), then the companion CPU will assume Mastership. As soon as the Preferred Master resumes operating normally, and its Synchronized Data has been updated, then the Mastership will transfer.
  • Page 60 User Manual Chapter 5 GFK-2409B Oct 2019 Figure 61: Switching Mastership Using a Momentary Pushbutton You may switch Mastership using a momentary pushbutton switch that is wired to a discrete input shared by the Hot Standby CPUs. In the example that follows, the switch is wired to discrete input Sw_Mstr_Pb (%I01011).
  • Page 61 User Manual Chapter 5 GFK-2409B Oct 2019 If a command to set SW_MSTR (%M01011) has been issued, then the system will operate in the following manner. • If both CPUs receive the command, and there is no Preferred Master, then the Mastership will change as soon as data synchronization is complete.
  • Page 62 User Manual Chapter 5 GFK-2409B Oct 2019 Variable Name Reference Function Description for additional security in revision control. %R9010 Program Additive Checksum %R9011 - Reserved %R9021 %R9022. Not used %R9023 Not used %R9024 Not used REM_SCN %R9025 Remote CPU’s Current Instantaneous PLC Scan time in Scan time msec.

  • Page 63: Advanced Topics

    User Manual Chapter 5 GFK-2409B Oct 2019 Advanced Topics PID Function Blocks The PID function block uses a data structure consisting of 40 registers. These registers contain not only configuration parameters, but also intermediate and final terms used in the internal calculations.
  • Page 64 User Manual Chapter 5 GFK-2409B Oct 2019 Figure 65 In this example, the PID parameters begin at PID_P01 (%R01001). For PID loop 01, there must be a synchronized data group configured that assures that registers %R01001 through %R01040 are transferred. You must include the registers associated with other PID function blocks as well.
  • Page 65 User Manual Chapter 5 GFK-2409B Oct 2019 Figure 66 2. Select the User Defined Alarms > Add Alarm… menu item. 3. Enter an Alarm Number and then the corresponding Alarm Description. Note: The Alarm Number must be within the numerical range 3840..4095. The descriptor ay be up to 60 characters in length.
  • Page 66 User Manual Chapter 5 GFK-2409B Oct 2019 6. Download the new Max-ON RX3i Configuration to the CPUs. In Your Application Folder 1. Move a user specified fault value into FLT_COD (%R9762). The fault value must be in the range 3840.4095 (decimal) inclusive and should correspond to the equivalent user-defined fault created in Max-ON RX3i Configuration Utility.
  • Page 67 User Manual Chapter 5 GFK-2409B Oct 2019 Figure 70 Alarm Table Organization The Alarm Table begins at %R9030 and ends at %R9190. The Alarm Table organization is shown below. Variable Name Register Description NUM_FLT %R9030 Number of Faults in Table (0 = empty; 33 = full) NUM_FLT [001] %R9031 Record 1 –...
  • Page 68 User Manual Chapter 5 GFK-2409B Oct 2019 Byte Offset Description Timestamp: Seconds (BCD) Timestamp: Minutes (BCD) Timestamp: Hours (BCD) Timestamp: Day of Month (BCD) Timestamp: Month (BCD) Timestamp: Year (BCD) Circuit Reference - lsb Circuit Reference - msb Alarm Subclass Alarm Class Bytes 0-5 These contain date and time information stored as BCD values.
  • Page 69 User Manual Chapter 5 GFK-2409B Oct 2019 Decimal Description Code Code 0002 Program Restart The CPU identified in the Source Column has transitioned from Stop to Run. 0003 Power Up Power has been restored to the CPU identified in the Source Column 0004 Invalid CPU ID The CPU identified in the Source Column does...
  • Page 70 User Manual Chapter 5 GFK-2409B Oct 2019 Decimal Description Code Code 0013 Genius Sync P Not used. LRC Error 0014 Not used. Genius Sync S LRC Error 0015 A defective configuration has been entered. Configuration There are either too many Fault %Q groups, or the reference range exceeds the capacity of the system.
  • Page 71 User Manual Chapter 5 GFK-2409B Oct 2019 Fault Class 01h - Discrete Inputs Decimal Description Code Code 0101 Circuit Offline The discrete input reference displayed in the Source Column has transitioned to an offline state. 0102 Not used 0103 Remote Rack Offline The remote drop corresponding to the discrete input reference displayed in the Source Column has transitioned to an...
  • Page 72 User Manual Chapter 5 GFK-2409B Oct 2019 Decimal Description Code Code 0120 Not used Fault Class 02h - Discrete Outputs Decimal Description Code Code 0201 Circuit Offline The device corresponding to the circuit reference number shown in the Source Column has transitioned to offline. 0202 Not used …...
  • Page 73 User Manual Chapter 5 GFK-2409B Oct 2019 Fault Class 05h – I/O LAN Alarms Decimal Description Code Code 1089 0501 Addition of Device The device corresponding to the circuit reference number shown in the Source Column has transitioned to online. 1090 0502 Loss of Device...

  • Page 74: Chapter 6: Configuring The Hot Standby Redundancy Cpus

    User Manual Chapter 6 GFK-2409B Oct 2019 Chapter 6: Configuring the Hot Standby Redundancy CPUs A Max-ON RX3i Project contains three Targets that are used to distinguish between hardware configurations for CPU A and CPU B, and the user application that is common to both of the CPUs.

  • Page 75: Configuring Plc A

    User Manual Chapter 6 GFK-2409B Oct 2019 Configuring PLC A Open the Hardware Configuration for PLC_A_HW In the Max-ON RX3i Project, select and expand the Hardware Configuration node of the PLC_A_HW target. Figure 72 Set the Max-ON RX3i Identity for PLC A The identity for CPU A is determined by the value set in the Logic Checksum Words CPU parameter located in the CPU’s Hardware Configuration for CPU A.
  • Page 76 User Manual Chapter 6 GFK-2409B Oct 2019 Figure 73 Set Memory Limits for PLC A The Max-ON RX3i drivers have memory requirements as defined below: Registers Registers Analog In Analog Out 50000 16384 2048 512 (minimum) (minimum) (minimum) (minimum) Select the Memory tab of the CPU configuration and verify that these values have been configured.
  • Page 77 User Manual Chapter 6 GFK-2409B Oct 2019 Figure 75 Add the Ethernet Interface module(s) to the appropriate slot(s) in the Hardware Configuration for PLC A and configure its parameters to match the Max-ON RX3i Configuration Summary. Figure 76 Configure EGD Exchanges for Sync LANS for PLC A Critical system data is transferred between the PLCs by way of Ethernet Global Data Exchanges.
  • Page 78 User Manual Chapter 6 GFK-2409B Oct 2019 Figure 77 Producer ID Modifications It might be necessary to revise the EGD configurations to match your unique system requirements (such as the IP addresses used.) The local producer ID may be configured by clicking on Ethernet Global Data and then setting the appropriate properties within the Inspector window.
  • Page 79 User Manual Chapter 6 GFK-2409B Oct 2019 Figure 79 PLC A – Primary PLC A – Secondary Note: All Ethernet modules within a PLC that produce and consume Ethernet Global Data must use the same Producer ID (i.e., IP address.) For instance, all the modules in PLC A that are configured for EGD exchanges might be addressed at IP 100.100.100.1, while all those in PLC B are configured for 100.100.100.2.
  • Page 80 User Manual Chapter 6 GFK-2409B Oct 2019 MxnCons1 (Primary LAN) Offset (Byte.Bit) Variable Ref Address Ignore Length Type Status %W49620 WORD TimeStamp %W49621 WORD %W40077 WORD MxnProd2 (Secondary LAN) Offset (Byte.Bit) Variable Ref Address Ignore Length Type Status %W49629 WORD %W40001 WORD MxnCons2 (Secondary LAN)
  • Page 81 User Manual Chapter 6 GFK-2409B Oct 2019 Figure 81 Add the Genius bus controllers to the appropriate slot(s) in the Hardware Configuration for PLC A and configure its parameters to match the Max-ON RX3i Configuration Summary. Figure 82 Serial Bus Address (SBA) All Genius bus controllers in PLC A must be configured to have their serial bus addresses set at 31.
  • Page 82 User Manual Chapter 6 GFK-2409B Oct 2019 Figure 83 Configure I/O Devices on the Primary Bus for PLC A Use the Bus I/O configuration summary from the Max-ON RX3i Configuration Utility as a guide for configuring the Genius devices that reside on the Genius bus. Add Genius devices to the GBC’s configuration and configure the Genius device parameters to match.
  • Page 83 User Manual Chapter 6 GFK-2409B Oct 2019 Note: VersaMax I/O is no longer configured automatically by the PLC Max-ON drivers. Please make certain that you use the Remote I/O Manager in Machine Edition to set and download the configurations. If there are no Secondary busses in the system then store the configuration into CPU A. Otherwise, configure the secondary bus as explained next.

  • Page 84: Configuring Plc B

    User Manual Chapter 6 GFK-2409B Oct 2019 Figure 87 Configuring PLC B Open the Hardware Configuration for PLC_B_HW In the Max-ON RX3i Project, select and expand the Hardware Configuration node of the PLC_B_HW target. Figure 88 Set the Max-ON RX3i Identity for PLC B The identity for CPU B is determined by the value set in the Logic Checksum Words CPU Parameter located in the CPU’s Hardware Configuration for CPU B.
  • Page 85 User Manual Chapter 6 GFK-2409B Oct 2019 Verify that the Number of Last Scans is set to 1. If it is not 1, change the parameter to this value. Figure 89 Set Memory for PLC B Normally, the memory in CPU B is configured the same as for CPU A. Please refer to the information used for CPU A, and make adjustments to the CPU B memory configuration, if necessary.
  • Page 86 User Manual Chapter 6 GFK-2409B Oct 2019 Figure 90 PLC A – Primary PLC A – Secondary Configuring the Hot Standby Redundancy CPUs...
  • Page 87 User Manual Chapter 6 GFK-2409B Oct 2019 Configure Ethernet Interface for Ethernet I/O LANS for PLC B (if used) Configure the Ethernet Interfaces used in conjunction with the Ethernet NIUs. Configure Genius Bus Controllers for PLC B (if used) Serial Bus Address All Genius bus controllers in PLC B should be configured to have their serial bus addresses set at 30.
  • Page 88 User Manual Chapter 6 GFK-2409B Oct 2019 Select the Export to File… right mouse menu item. Figure 92 Specify a file name for the configuration, or use the default name PLC_A_HW.hwc Figure 93 Configuring the Hot Standby Redundancy CPUs...
  • Page 89 User Manual Chapter 6 GFK-2409B Oct 2019 Select the Hardware Configuration node for PLC_B_HW target. Select the Import from File… right mouse menu item Figure 94 Specify the file name used in Step 3 (default name PLC_A_HW.hwc). Figure 95 Now modify the Hardware Configuration for PLC_B_HW Target to match the parameters of PLC B in your system.

  • Page 90: Chapter 7: Configuring The I/O Devices

    Ethernet I/O bus. For Max-ON RX3i the Ethernet devices may consist of PACSystems RX3i ENIUs and/or Series 90-30 ENIUs. For a complete description of how to configure and use the PACSystems RX3i ENIUs, please see GFK-2434, titled PACSystems RX3i Ethernet Network Interface Unit. A summary of the process to configure this ENIU is as follows: 1.

  • Page 91: Configuring The Genius I/O Devices

    User Manual Chapter 7 GFK-2409B Oct 2019 Figure 97 6. Set the EGD Local Producer ID in the controllers. 7. Create EGD Exchanges in the Primary controller (PLC A) to match the EGD exchanges in each ENIU. 8. Create EGD Exchanges in the Secondary controller (PLC B) to match the EGD exchanges in each ENIU.
  • Page 92 User Manual Chapter 7 GFK-2409B Oct 2019 Additionally, you must set the I/O to operate properly for redundancy: • Dual I/O busses • Hot Standby controller Genius and Field Control I/O While you are configuring the Genius I/O, you must configure extra parameters that govern system operation with respect to redundant PLCs and redundant (dual) Genius I/O busses.
  • Page 93 Genius VersaMax I/O 1. Add the PACSystems VersaMax target(s) to your Machine Edition Project by selecting the Add Target > Emerson Remote I/O > VersaMax Genius menu. Figure 99 2. Click on the Target and rename it to match your application conventions.
  • Page 94 User Manual Chapter 7 GFK-2409B Oct 2019 Figure 100 5. Select this as the active target. 6. Set the Comm port characteristics. 7. Connect a serial programming cable to your workstation and to the VersaMax I/O drop. 8. Store the configuration into the drop. 9.
  • Page 95 User Manual Chapter 7 GFK-2409B Oct 2019 Figure 101 2. Using the File menu, click on Restore Project... Figure 102 3. Navigate to the PAC Components directory, then to the Remote Drops LD directory. Open the desired Remote Drop directory, RemoteDrop CPU35x, 36x, 374 (small), for example.
  • Page 96 User Manual Chapter 7 GFK-2409B Oct 2019 Figure 103 When you click on Open, a new project will be added to the PAC Navigator window. 4. Give your project a descriptive name in the Machine Edition Navigator. Remote Drop Status Word A remote drop always places important status information into its local references at %I00001 through %I00016 inclusive.
  • Page 97 User Manual Chapter 7 GFK-2409B Oct 2019 Bit Offset Description Offline Overrides Present PLC Low Battery Config Mismatch Loss of I/O Module Loss of Option Module Option Module Hard Fault Option Module Soft Fault System Fault Present I/O Fault Present Program Changed HW Config Changed Power Up...
  • Page 98 User Manual Chapter 7 GFK-2409B Oct 2019 In the Global Data Tab At the GBC’s Address: Input 1 Address %I00001 Input 1 Length always 0 Input 2 Address %AI00001 Input 2 Length always 0 Output 1 Address %I00001 Output 1 Length 16 plus the number of Discrete Inputs installed Output 2 Address %AI00001...
  • Page 99 User Manual Chapter 7 GFK-2409B Oct 2019 In the Settings Tab Serial Bus Address (SBA): Any address from 0 to 29 is acceptable. (Note: Normally a Genius Handheld Monitor normally is set for SBA=0. It is standard practice to avoid 0 when using Field Control or Genius I/O.) Status Reference Type: %I00449 for M23, M31, and M40 drop folders...
  • Page 100 User Manual Chapter 7 GFK-2409B Oct 2019 Output 2 %AQ00001 Output 2 Length always 0 The table shown below should be used to configure the Genius bus controller(s) in a remote drop. The table lists the register references that must be entered the Logic Developer PLC hardware configuration based upon the template folder that was used to create the remote drop.
  • Page 101 User Manual Chapter 7 GFK-2409B Oct 2019 Configuring the Range 1. In Logic Developer PLC, open the Remote Drop project. 2. Using the navigator, open the Block named mxn_cfg. 3. Edit the first rung of data moves. 4. In the first MOVE function, a constant is moved into the reference named M_Q_ST (Master CPU Starting Q Ref) Enter the starting reference for the outputs that are to be received from the Hot Standby PLCs.
  • Page 102 User Manual Chapter 7 GFK-2409B Oct 2019 Configuring the Range 1. In Logic Developer PLC, open the Remote Drop project. 2. Using the navigator, open the Block named mxn_cfg. 3. Edit the second rung of data moves. 4. In the first MOVE function, a constant is moved into the reference named M_AQ_ST (Master CPU Starting AQ Ref) Enter the starting reference for the outputs that are to be received from the Hot Standby PLCs.
  • Page 103 User Manual Chapter 7 GFK-2409B Oct 2019 Figure 106 Configuring the I/O Devices...

  • Page 104: Chapter 8: Diagnostic Tools

    User Manual Chapter 8 GFK-2409B Oct 2019 Chapter 8: Diagnostic Tools Max-ON RX3i Diagnostic Tools software provides diagnostic functions that may be used to obtain both real-time and historical operating information from your Hot Standby system. The Diagnostic Tools are provided by a PAC View project that is used to monitor the redundant system.
  • Page 105 User Manual Chapter 8 GFK-2409B Oct 2019 Figure 108 Navigate to the PAC Components directory, then to the Diagnostics VIEW. Make certain that the selection for Files of Type has been set to PAC Machine Edition *.zip). Figure 109 When you click on Open, a new project will be added to the PAC Navigator window. Figure 110 4.

  • Page 106: Step 2 - Configure Ethernet Connections To The Plcs

    User Manual Chapter 8 GFK-2409B Oct 2019 Step 2 – Configure Ethernet Connections to the PLCs In order to conduct data transfers between Max-ON RX3i Diagnostics and the Hot Standby PLCs, you need to establish an Ethernet communication connection to the PLCs. To configure the Ethernet addresses of the PLCs in the View Project: 1.

  • Page 107: Step 3 - Use The Max-On Rx3I Diagnostic Tool

    User Manual Chapter 8 GFK-2409B Oct 2019 This will launch the View project to run on your PC Step 3 – Use the Max-ON RX3i Diagnostic Tool Once the Diagnostic Tool starts on your PC, the main Diagnostics page will be displayed: Figure 113 System Status Clicking on this tab displays the Real-time Status page.

  • Page 108: System Status

    User Manual Chapter 8 GFK-2409B Oct 2019 System Status You may view items that relate to the current operating characteristics of your system on the System Status page. An example is shown in the picture above. PLC A and PLC B Status Indicates the operating status of the corresponding PLC, either Running or Stopped.

  • Page 109: Alarms

    User Manual Chapter 8 GFK-2409B Oct 2019 Alarms Historical information is stored in the alarm table. This table contains archived information for up to 32 alarm records for each PLC. The records store information for both system alarms and optional user-defined alarms. Each alarm record consists of an identifier for the event that initiated the entry, along with a date/time stamp to indicate when the event occurred.

  • Page 110: Project Information

    You may view certain items that relate to the general nature of your system. Select the Project Info tab Figure 115 PLC Catalog Number The catalog number of the Emerson controller that is running the Max-ON RX3i project. SW Version...

  • Page 111: Authorization

    User Manual Chapter 8 GFK-2409B Oct 2019 Authorization You may view the information related to the authorization of your system by selecting the Authorization tab. Figure 116 Status The Status field indicates whether the system is running on a Max- ON RX3i CPU (IC695CMU310), or running in Demo mode on a standard RX3i CPU (IC695CPU310).

  • Page 112: General Max-On Rx3I Considerations

    User Manual Appendix A GFK-2409B Oct 2019 Appendix A System Consideration General Max-ON RX3i Considerations There are several considerations and recommendations that should be taken into account when defining a Max-ON RX3i system. This appendix summarizes the main items that the application developer should keep in mind when planning and developing such a system.
  • Page 113 User Manual Appendix A GFK-2409B Oct 2019 3. Prior to the call to HBR_000 in the _MAIN Block, enter a rung that sets AUTSWP (%M1012) to ON. 4. Store the Logic into CPU A. 5. Store the Logic into CPU B. Manual Mode The second method is to configure the CPUs to execute in Constant Sweep mode.

  • Page 114: Hot-Swapping Ic693/Ic694Bem331 Modules

    User Manual Appendix A GFK-2409B Oct 2019 Hot-Swapping IC693/IC694BEM331 Modules Genius Bus Controller modules IC693/694BEM331 that are included in a Max-ON redundancy system should not be removed from or installed in the PLC that is operating as a Master. If a module is removed from the Master and then reinstalled, the outputs for that module will not be enabled until the next Backup-to-Master transition.
  • Page 115 User Manual Appendix B GFK-2409B Oct 2019 Appendix B Frequently-Asked Questions Does Max-ON RX3i Configuration Tools generate my Logic Developer PLC hardware configuration? No. You must create the Hardware Configuration in the Logic Developer PLC project to match the parameters defined in the Max-ON RX3i Configuration Tool. Is the hardware configuration in the Max-ON RX3i Project used in any fashion? Yes.
  • Page 116 User Manual Appendix B GFK-2409B Oct 2019 controller and set Output at Start to Be Enabled. Store the new configuration into the CPU. Make certain that you do this for both CPUs. Redundant operation is affected adversely by these settings. Don’t forget to change the configuration to Disabled when you are ready to run the Max-ON RX3i drivers again.
  • Page 117 User Manual Appendix C GFK-2409B Oct 2019 Appendix C Quick Start Guide Using Ethernet This appendix uses an example Max-ON RX3i Redundant system with two controllers to give an overview of the steps needed to set up Max-ON RX3i systems with Ethernet NIUs for the I/O.
  • Page 118 User Manual Appendix C GFK-2409B Oct 2019 Figure 118 3. Using the File menu, click on Restore Project Figure 119 4. Place the Max-ON RX3i Installation CD in your CD drive and navigate to the Quick Start directory. Make certain that the selection for Files of Type has been set to PAC Machine Edition (*.zip).
  • Page 119 User Manual Appendix C GFK-2409B Oct 2019 Figure 120 When you click on Open, a new project will be added to the PAC Navigator window. Give your project a descriptive name in the Machine Edition Navigator. The Quick Start project is set up with controller targets named Primary_Controller (PLC A) and Secondary_Controller (PLC_B) and 3 ENIUs named ENIU11, ENIU12, ENIU13.
  • Page 120 User Manual Appendix C GFK-2409B Oct 2019 • For Consumed Exchanges, change the Producer ID of the Exchange 11. Set default values for variables. 12. Download configurations to the Targets. When downloading to new or unknown hardware, first set the physical port property of the device in the programmer to a serial comm port (com1) and connect via a serial cable to the power supply port.
  • Page 121 User Manual Appendix C GFK-2409B Oct 2019 Double-click on the config.mx3 file. This will launch the Max-ON RX3i Configuration Utility that can used to define the parameters of the Redundant System. Figure 123 16. When the parameters of the Redundant Systems are entered or modified using the Configuration Utility, the cfg_dat C block is updated in the Max-ON Project directory.
  • Page 122 User Manual Appendix C GFK-2409B Oct 2019 17. Select the C Block Update… right mouse menu and select the cfg_dat C Block gefelf file Figure 125 18. At this point the updated Configuration Utility parameters have been added to the Max-RX3i project.
  • Page 123 User Manual Appendix D GFK-2409B Oct 2019 Appendix D Updating an Existing Application This appendix explains how to upgrade the Max-ON program blocks in your application to a newer version of Max-ON using the PAC Toolchest. Overview The general sequence for updating an application is as follows: 1.

  • Page 124: Updating An Existing Max-On Rx3I Application

    User Manual Appendix D GFK-2409B Oct 2019 • Adjust the target’s Ethernet I.P. address to match the address of the Backup PLC. (Or if using a serial connection, connect to the programming port on the Backup PLC.) • Download (Logic only) the target named PLC_COMMON_CODE into the Backup PLC.
  • Page 125 User Manual Appendix D GFK-2409B Oct 2019 Figure 126 3. Right-click on the project and the following menu list will be displayed. Figure 127 4. Select Back UP and the following dialog box will be displayed. Updating an Existing Application...

  • Page 126: D-1.2 Updating From Releases Prior To 3.14

    User Manual Appendix D GFK-2409B Oct 2019 Figure 128 5. Navigate to the directory in which you wish to save the backup copy of the project. 6. Make certain that the file is saved as a Zip File (*.zip), and then click on Save. D-1.2 Updating from Releases Prior to 3.14 In release 3.14, the system state values are transferred by way of Ethernet Global Data...

  • Page 127: D-1.3 Add Egd Exchanges To Plc A

    User Manual Appendix D GFK-2409B Oct 2019 D-1.3 Add EGD Exchanges to PLC A Select the target named PLC_A_HW. Right-click on the target to display the pop-up menu. Click on “Add Component ►Ethernet Global Data”. A new component named “Ethernet Global Data”...
  • Page 128 User Manual Appendix D GFK-2409B Oct 2019 Figure 130 Primary LAN EGD Consumed Exchange In the Navigator window, expand Ethernet Global Data to reveal the Consumed and Produced exchanges. Figure 131 Right-click on Consumed Exchanges. The following pop-up menu will be displayed Updating an Existing Application...
  • Page 129 User Manual Appendix D GFK-2409B Oct 2019 Figure 132 Click on New to create the first Consumed Exchange. The default name for the exchange is ConsExch1. In the Inspector window, set these properties as follows: Name Set to MxnCons1 Producer ID Set to the IP address of the Primary Ethernet module in PLC B.
  • Page 130 User Manual Appendix D GFK-2409B Oct 2019 Figure 134 In the InfoViewer window, click on the Add button to add a new item to the table. The window will appear as shown below. Figure 135 Complete the configuration for the exchange by editing the parameters as illustrated in the table that follows.
  • Page 131 User Manual Appendix D GFK-2409B Oct 2019 Name Set to MxnProd1 Exchange ID Defaults to 1 Adapter Name Set to location of Primary ETM (normally Rack 0, Slot 4) Destination Type Defaults to Unicast Destination Set to the IP address of the Primary ETM in PLC B Produced Period Set to 10 Reply Rate...
  • Page 132 User Manual Appendix D GFK-2409B Oct 2019 Figure 139 Complete the configuration for the exchange by editing the parameters as illustrated in the table that follows. MxnProd1 (Primary LAN) Offset (Byte.Bit) Variable Ref Address Ignore Length Type Status %W49619 WORD %W40001 WORD Secondary LAN EGD (optional)

  • Page 133: D-1.4 Add Egd Exchanges To Plc B

    User Manual Appendix D GFK-2409B Oct 2019 MxnProd2 (Secondary LAN) Offset (Byte.Bit) Variable Ref Address Ignore Length Type Status %W49629 WORD %W40001 WORD D-1.4 Add EGD Exchanges to PLC B Select the target named PLC_B_HW. Right-click on the target to display the pop-up menu. Click on “Add Component ►Ethernet Global Data”.
  • Page 134 User Manual Appendix D GFK-2409B Oct 2019 Set the Producer ID Go to the Navigator window and click on Ethernet Global Data so that you may edit the properties. Go to the Inspector window and edit Local Producer ID so that the IP address corresponds to the IP address that was set for the Primary LAN Ethernet module in PLC B.
  • Page 135 User Manual Appendix D GFK-2409B Oct 2019 Figure 143 Click on New to create the first Consumed Exchange. The default name for the exchange is ConsExch1. In the Inspector window, set these properties as follows: Name Set to MxnCons1 Producer ID Set to the IP address of the Primary Ethernet module in PLC A Group ID Defaults to 0...
  • Page 136 User Manual Appendix D GFK-2409B Oct 2019 Figure 145 In the InfoViewer window, click on the Add button to add a new item to the table. The window will appear as shown below. Figure 146 Complete the configuration for the exchange by editing the parameters as illustrated in the table that follows.
  • Page 137 User Manual Appendix D GFK-2409B Oct 2019 Name Set to MxnProd1 Exchange ID Defaults to 1 Adapter Name Set to location of Primary ETM (normally Rack 0, Slot 4) Destination Type Defaults to Unicast Destination Set to the IP address of the Primary ETM in PLC A Produced Period Set to 10 Reply Rate...
  • Page 138 User Manual Appendix D GFK-2409B Oct 2019 Figure 150 Complete the configuration for the exchange by editing the parameters as illustrated in the table that follows. MxnProd1 (Primary LAN) Offset (Byte.Bit) Variable Ref Address Ignore Length Type Status %W49619 WORD %W40001 WORD Secondary LAN EGD (optional)

  • Page 139: D-1.5 Update The Max-On Drivers

    User Manual Appendix D GFK-2409B Oct 2019 Produced Exchange Refer to the procedure used for the Primary exchange and then set the table properties as shown below: MxnProd2 (Secondary LAN) Offset (Byte.Bit) Variable Ref Address Ignore Length Type Status %W49629 WORD %W40001 WORD...
  • Page 140 User Manual Appendix D GFK-2409B Oct 2019 Figure 152 Press the Open button. This will add the drawer to your Toolchest. 2. Expand the MaxON_Components folder in the PLC_COMMON_CODE Target in your project to display the current set of Max-ON Drivers. If you examine the Block Properties of each Block, you can see your current Block revision, such as v3.04.
  • Page 141 User Manual Appendix D GFK-2409B Oct 2019 4. Add the version Max-ON RX3i Drivers to the MaxON_Components folder directory using the Ctrl-Drag-and-Drop operation from the Toolchest Figure 154 The Blocks must be added to the Machine Edition Project in the following order: a.
  • Page 142 User Manual Appendix D GFK-2409B Oct 2019 Figure 155 6. MaxON_RX3i_MAIN Block is also available in the Toolchest Drawer. This Block has a comment in the first rung that details the revision history. 7. Validate your Max-ON RX3i application to verify that all Max-ON Driver blocks are properly located in the Project.
  • Page 143 Emerson product remains solely with the purchaser. © 2019 Emerson. All rights reserved. Emerson Terms and Conditions of Sale are available upon request. The Emerson logo is a trademark and service mark of Emerson Electric Co. All other marks are the property of their respective owners.

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