cost-effective unity premium hot standby solution
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Cost-effective Unity Premium Hot Standby Solution
Presenter – Tom RoyalAmericas Business SupportEnd User Domain – Automation BU
Call-in number 1-866-758-0236Passcode 3306817
Schneider Electric 2Automation BU – End User Domain - Americas Business Support
● Overview
● Typical architectures
● Competition
● Sales Arguments and Value Proposition
● Migration from Standalone
● Targeted applications and opportunities
● Operation and Rollover
● Positioning with Quantum
Contents
Schneider Electric 3Automation BU – End User Domain - Americas Business Support
●Automation system keeps running despite a controller failure
●Primary PLC with a Standby PLC as backup
●Running guaranteed only for the first failure
●No guarantee for a second failure in the system (unless the first one is repaired)
Introduction What is HSBY?
Schneider Electric 4Automation BU – End User Domain - Americas Business Support
● The UNITY Premium Hot Standby System is designed foruse where downtime cannot be tolerated.
● Two backplanes are configured with identical hardware, firmware** and application program.
● One of the PLCs acts as the Primary. The Primary Controller updates the Standby Controller at the beginning of each scan.
● Primary and Standby States are switchable. Either controller can be put in the primary state.
● The remote I/O (STB,OTB… ) is never aware of the existence of two PLCs.
● The CPU-sync link is a point-to-point connection dedicated to application data exchange and hot standby system diagnostics.
Introduction HSBY overview
Schneider Electric 5Automation BU – End User Domain - Americas Business Support
Typical Architecture with Redundant I/O & SCADA Network
ETG1000
Ethernet I/O Scanner RING
CPU-syncLink
Primary Premium
Standby Premium
Ethernet TCP/IP network #2
ET
YE
TY
ET
YE
TY
ET
Y
ET
Y
Tesys
U
Modbus
XBT-
GT
Mom
entu
m
IO
STB
OTB
Ethernet TCP/IP network #1
VIJEO CITECT
ATV61
Schneider Electric 6Automation BU – End User Domain - Americas Business Support
o Easy to Program● Design and commission as quickly as a standalone application● No specific user programming.● Access to all Unity Pro and IEC1131-3 features
o Easy to Operate● Hot Swap and auto-reconfiguration ability for selected I/O modules● Bumpless rollover for selected I/O modules● Transparent rollover for SCADA & HMI (IP swapping)
o Efficient● Uses our experience in HSBY systems● Efficient data context exchange (no application programming)● Uses the very powerful Unity Premium hardware● Execution performances
Value Propositions Easy to program and operate
Schneider Electric 7Automation BU – End User Domain - Americas Business Support
Typical Premium HSBY Architecture STB I/O islands over Ethernet
Premium PRIMARY
Premium STANDBY
Ethernet I/O ring 10/100 Mbps
Advantys STB
Modicon M340 Momentum
SCADABriefly:•Specific Hot Standby CPUs required.•Hardware redundancy – not software.•CPUs are linked with Ethernet crossover cable.•I/O located remotely through Ethernet
network (ring topology).•Local rack I/O can also be used (redundant)
Briefly:•Specific Hot Standby CPUs required.•Hardware redundancy – not software.•CPUs are linked with Ethernet crossover cable.•I/O located remotely through Ethernet
network (ring topology).•Local rack I/O can also be used (redundant)
Premium HSBY positioningPerformance
Availability Rate
Easy usage
Cost effective
Schneider Electric 8Automation BU – End User Domain - Americas Business Support
Typical Rockwell ControlLogix ArchitectureFlex I/O islands over ControlNet
Briefly :•Hardware redundancy with a dedicated redundancy module•Dual attachment topology
Briefly :•Hardware redundancy with a dedicated redundancy module•Dual attachment topology
Premium HSBY vs ControlLogix
Performance
Availability Rate
Easy usage
Cost effective
Premium HSBY EthI/O
ControlLogix Flex I/O
Schneider Electric 9Automation BU – End User Domain - Americas Business Support
Typical Siemens architectureET200 I/O islands over Profibus
Briefly :•Software redundancy solution•Dual attachment topology
Briefly :•Software redundancy solution•Dual attachment topology
Premium HSBY vs SoftRed
Performance
Availability Rate
Easy usage
Cost effective
Premium HSBY EthI/O
SoftRed ET200 I/O
Schneider Electric 10Automation BU – End User Domain - Americas Business Support
IM 153-2 with ET200M
IM 157 with PA bus
Y-Link with DP bus
Rack 0 Rack 1
Briefly :•Hardware redundancy solution•Dual attachment topology
Briefly :•Hardware redundancy solution•Dual attachment topology
Premium HSBY vs S7-400HPerformance
Availability Rate
Easy usage
Cost effective
Premium HSBY EthI/O
S7-400H ET200 I/O
Typical Siemens S7 400H architectureET200 I/O islands over Profibus
Schneider Electric 11Automation BU – End User Domain - Americas Business Support
Market segmentation Performance
SCANTime
SoftwareSoftware redundancyredundancy
HardwareHardwareRedundancyRedundancy
Slow
Performance
Slow S/O onRemote I/O
Fast S/O onRemote I/O
Premium WSBY
ET
Y
ET
Y
Premium Hot Standby
Fast S/Oon CPU &Rack I/O
Slow S/Oon CPU &Rack I/O
Very FastFast except Small App Fast
Quantum Hot StandbyAB ControlLogix
Omron CS1D
SiemensSoftRed
Siemens S7400H
Schneider Electric 12Automation BU – End User Domain - Americas Business Support
Pricing policy
●Comparison of:●Premium HSBY with STB I/O over Ethernet●Siemens SoftRed with ET200 I/O over Profibus●Siemens S7400H with ET200 I/O over Profibus●Rockwell Contrologix with Flex I/O over ControlNet
Small HSBy configuration - Country
PLCPLC
PLCPLC
I/OsI/Os
I/OsI/Os
0
5000
10000
15000
20000
25000
30000
Premium + STB S7-300 S7-400 + ET200M ControlLogix
Net Price in LC
Medium HSBy configuration - Country
PLCPLCPLC
PLC
I/OsI/Os
I/OsI/Os
05000
1000015000
2000025000
3000035000
4000045000
Premium + STB S7-300 S7-400 + ET200M ControlLogix
Net Price in LC
Large HSBy configuration - Country
PLCPLCPLCPLC
I/OsI/Os
I/OsI/Os
010000
2000030000
4000050000
6000070000
8000090000
Premium + STB S7-300 S7-400 + ET200M ControlLogix
Net Price in LC
Schneider Electric 13Automation BU – End User Domain - Americas Business Support
oStrong points of the offer:● High Performance in terms of scan time, CPU & rack I/O performance
while keeping “bumpless” warranty (Rockwell / Siemens SoftRed)● Just enough global functionalities for targeted markets (SI)● Flexibility in terms of rollover performances and availability rate● Non-specific HSBY programming (SI – Siemens SoftRed)● IP address swapping and Ethernet choice (SI - Everybody)● Long lasting investment (EU)● Ring topology gives higher redundancy (better than Siemens/Rockwell).
Sales arguments
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oWeak points of the offer (and how to address them):● Fieldbus compatibility with instrumentation (SI). Go through gateways,
push architectures with Ethernet compatible devices, move to Quantum● Process stopped while doing heavy process modifications (EU). Address
applications where process can be stopped sometimes or where application updates are not requested
● No Remote I/O double attachment. Propose in-rack I/O - put I/O island in a cabinet with switch or use remote M340 or move to Q HSBY
● No Power Supply redundancy. Duplicate the STB islands or move to Q.● No Automatic Download from Primary to Standby (EU)
Sales arguments
Schneider Electric 15Automation BU – End User Domain - Americas Business Support
oGlobal saleso ~100 unit -
equally split between the two part numbers.
Worldwide Sales Figures
Number of CPUs
0
10
20
30
40
50
60
70
80
Telecom
Power
Water
F&B
Marine
Mining
Chem/PharmaO&G
Infra
Chem /Pharma
o By market segment
No quality issues so far!
Schneider Electric 16Automation BU – End User Domain - Americas Business Support
oFault Tolerant Solution for Non Time-critical Applications where:
● Production downtime is expensive● Valuable material is processed● Production restart costs are high● Skilled monitoring, maintenance personnel are rare
Targeted Applications
Infrastructure
Power TunnelAirportWater
Schneider Electric 17Automation BU – End User Domain - Americas Business Support
Power production ● Hydroelectric dams
Road infrastructure● Tunnel Lighting,
Ventilation and Signaling
● Road Signaling
●River infrastructure● Locks
●Airport infrastructure● Runway lighting
and signaling
Targeted Application Examples
Water ● Water treatment● Desalination
Schneider Electric 18Automation BU – End User Domain - Americas Business Support
HSBY Operation and Rollover Premium Hot Standby System Overview
It is not possible to have non-ambiguous diagnostics of the Premium Hot Standby system with only one link between the two PLCs (CPU-sync link). Therefore an Ethernet module in each PLC is configured, then they’re linked with an Ethernet cable (with or without switches).
CPU SYNCCPU SYNCCPU SYNCCPU SYNC
ETY SYNC ( Monitored )ETY SYNC ( Monitored )ETY SYNC ( Monitored )ETY SYNC ( Monitored )
Schneider Electric 19Automation BU – End User Domain - Americas Business Support
HSBY Operation and Rollover Interpreting LED blink patterns
Display Block Indicators: ERR: faults relating to the Processor Module RUN: Program Execution States and Hot Standby Mode I/O: faults on another Station Module or Configuration fault TER: activity on the Terminal port ACT: Blinking: indicates communication between Primary and Standby Controllers STS: Blinking: the System is Redundant and Data are exchanged from Primary to Standby Steady On: the System is not Redundant or Copro is booting from Power-on to end of self-tests Steady Off: Copro Auto Tests Failed
State of RUN LED dependson the HSBY Mode: PRIMARY STANDBY OFFLINE STOP
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In accordance with IEC Standards, Unity uses global objects called System Bits and System Words:
oSystem Words:● %SW60 - Read / Write the Premium Hot Standby Command Register.● %SW61 – Read the Premium Hot Standby Status Register.● %SW62/63/64/65 - Reverse Registers reserved by the Reverse
Transfer process. Written by the Application program Controlled and transferred at each scan to the Primary controller.
● %MW0 to %MW99 – Non-Transfer Area
HSBY Operation and Rollover System Words & Bits
Schneider Electric 21Automation BU – End User Domain - Americas Business Support
HSBY Operation and Rollover Database Transfer Diagram
Located Variables (maximum 128 kilobytes)
All Unlocated variables up to 300 kb (depending on the CPU** )
The Database is built automatically by the Primary PLC Operating System and sentat each Primary PLC cycle to the Standby PLC. This exchange is performed via the
embedded Ethernet coprocessor of the two HSBY PLCs.
**CPU Max data sizeTSX H57 24 M 193 kbytesTSX H57 44 M 440 kbytes
PrimaryPrimary RedundantRedundant
Database
Reverse registers
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HSBY Operation and Rollover Database Transfer Timing - 1
1 – Time required to copy the application data to the communication link layer.
2 – The Hot Standby system is thus able to transfer a data zone from the “Primary” PLC to the “Standby” PLC
At the start of each scan cycle, the contents of the data memory in the “Primary” PLC are transferred to the “Standby” PLC.
The Standby PLC refreshes its own OUTPUTs managed in the first section
Schneider Electric 23Automation BU – End User Domain - Americas Business Support
HSBY Operation and Rollover Database Transfer Timing - 2
1 We use a CYCLIC or a PERIODIC mode and the time to transfer the data is less than the scan time of the PRIMARY.
INPUTINPUT
WAITWAIT ++
HSBY CoproHSBY Copro
1 section1 section
OUTPUTOUTPUT
INPUTINPUT
WAIT WAIT ++
HSBY CoproHSBY Copro
INPUTINPUT
HSBY CoproHSBY Copro
ProgramProgram
OUTPUTOUTPUT
INPUTINPUT
HSBY CoproHSBY Copro
OUTPUTOUTPUT OUTPUTOUTPUT
Data exchangeData exchange
Data exchangeData exchange
No impact on the PRIMARY cycle time
Schneider Electric 24Automation BU – End User Domain - Americas Business Support
HSBY Operation and Rollover Database Transfer Timing - 3
2 We use a CYCLIC or a PERIODIC mode and the time to transfer the data is greater than the scan time of the PRIMARY.
INPUTINPUT
WAITWAIT++
HSBY CoproHSBY Copro
1 section1 section
OUTPUTOUTPUT
INPUTINPUT
INPUTINPUT
HSBY CoproHSBY Copro
ProgramProgram
OUTPUTOUTPUT
INPUTINPUT
HSBY CoproHSBY Copro+ WAIT+ WAIT
Data exchangeData exchange
Effect: Output flickers on in-rack I/O (not I/O Scanning) because the outputs are managed in parallel
Data exchangeData exchange WAITWAIT++
HSBY CoproHSBY Copro
PRIMARY cycle time is affected
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HSBY Operation and Rollover X-Bus (local) I/O Rollover Time
The rollover time is the time between the last update of an output by the old Primary and the first update of that same output by the new Primary.
********
** ** Worst case for the rollover performanceWorst case for the rollover performance
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Unity Pro Configuration Information Tab
In this screen Hot Standby status is clearly displayed.
Schneider Electric 27Automation BU – End User Domain - Americas Business Support
Unity Pro Configuration Hot Standby Tab
“Topological address (slot #) of the monitored Ethernet module”: This dropdown is populated by the addresses of the existing ETY modules.
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HSBY Operation and Rollover Selection of Primary PLC
A & B designations:• PLC with lowest MAC address in Ethernet copro becomes “A”
MAC1 = 00.80.F4.01.6E.E1 MAC2 = 00.80.B4.01.6E.E1Which becomes Primary:• First one powered up with valid application becomes Primary • If powered up simultaneously and both have valid applications – A becomes Primary• If only one has valid application – it becomes Primary
How to power down?• Stop Standby first to avoid needless rollover
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HSBY Operation and Rollover Common Rollover Events
• Power supply failure on the CPU rack (slowest rollover because of wait for watchdog to time out)
• Application program fault that generates a HALT state
• Hardware or firmware fault on the CPU module
• Hardware or firmware fault on the monitored ETY module
• Cable disconnected between the monitored ETY and the first hub/switch
• A CPU-sync link failure - (only when PLC is Standby, no rollover if Primary)
Schneider Electric 30Automation BU – End User Domain - Americas Business Support
Aspects to consider during a migration:o Hardware
● ETY4103/ETY5103 (firmware must be upgraded when migrating)● Non-extendable racks : TSXRKY6 / TSXRKY8 / TSXRKY12
o Application program● 100 first memory words (%MW) are not exchanged between Primary and
Standby● First section in Standby not scanned● No event tasks, rising edges, SAVE_PARAM commands
o Ethernet ● Do not use consecutive Ethernet addresses in your standalone configuration● Do not use Global Data service/FDR/DHCP service
o Testing ● Do not use consecutive Ethernet addresses in your standalone configuration● PLC will always be designated “A” in standalone -> this must be considered
if used in application● CPU-sync link NOK -> since the standby PLC is not present.● Allow for longer CPU scan time (because HSBY CPU takes some time to
exchange data between processor and coprocessor):
Migrating from a standalone application
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HSBY Operation and Rollover Online Modifications
Reminder: Logic mismatch is not allowed in a Premium Hot Standby system.
PRIMARY is PRIMARY is AA and STANDBY is and STANDBY is BB
AA BB
Modify the application online in the PRIMARY Modify the application online in the PRIMARY
- The Primary is still active- The Primary is still active- Standby goes OFFLINE - Standby goes OFFLINE
Save application in the PC Save application in the PC
Transfer modified application to CPU Transfer modified application to CPU B B
- The Primary is still active - The Primary is still active - After transfer, the CPU- After transfer, the CPU B B is in STOP/OFFLINE is in STOP/OFFLINE RUN command on the RUN command on the BB
- The Primary is still active - The Primary is still active - After RUN the CPU - After RUN the CPU BB is in RUN/STANDBY is in RUN/STANDBY
RUNRUN
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HSBY Operation and Rollover OS Upgrade Procedure
PRIMARY is PRIMARY is AA and STANDBY is and STANDBY is BB
AA BB
Through Unity or the application, set bit 4 of %SW60 Through Unity or the application, set bit 4 of %SW60 on the PRIMARY on the PRIMARY
STOP the PRIMARY STOP the PRIMARY AA STANDBYSTANDBY B B becomes the PRIMARY becomes the PRIMARY
Download the new OS with UNITY LOADER and Download the new OS with UNITY LOADER and the application to the application to A A
Connect unity on Connect unity on BB and STOP the PLC and STOP the PLC PLC PLC AA becomes PRIMARY / becomes PRIMARY / BB STANDBY STANDBY
Put PLC A in RUNPut PLC A in RUN PLC PLC A A becomes the STANDBYbecomes the STANDBY
Download the new OS with UNITY LOADER and Download the new OS with UNITY LOADER and the application to the application to B B
Put the PLC in RUNPut the PLC in RUN PLC PLC B B becomes the STANDBYbecomes the STANDBY
Through Unity or the application, reset bit 4 of %SW60 Through Unity or the application, reset bit 4 of %SW60 on the PRIMARY on the PRIMARY
RUNRUN RUNRUN
Reminder : OS mismatch is supported by a Premium Hot Standby system.
r
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HSBY Operation and Rollover Verifying the Health of a Standby System
•Hot Standby Diagnostics are displayed in the Status Registerof each Hot Standby PLC (%SW61).
•More Diagnostic information can be obtained by monitoring PLC States, Module Bits and Words (%S ,%SW).
•Diagnostic information can be stored in non-transfer %MW area (%MW0-99).
•This Diagnostic information can be sent from Standby to Primary PLC, using the Reverse Transfer Registers (%SW62 - %SW65).
•Health Messages are exchanged between the Primary and Standby.
•If there is a fault in the Primary, Standby is notified and assumes Primary role.
•If there is a fault in the Standby, Primary continues to operate as Standalone.
•Monitored ETY Modules periodically verify communication with each other.
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Functional positioning with Quantum
Monitored Ethernet S/O Yes Through DFBRedundant in-rack I/O Yes Yes in mandatory 3rd Rack
through applicationMulti Modbus Master
CommunicationYes No
Number of Available CPUs 2 1 non SIL, 1 SIL2System Words 4 Reverse Registers 2 Reverse and less Status Info
Consequence of Logic Mismatch
Standby goes offline user choice
Dual PS for CPU No YesSIL rating No SIL2
CPU Sync Link without transceivers
100 meters copper 2 km fiber optic
Remote I/O Only on Ethernet Ethernet or Local Shared in Double Attachment 4.5 km
Front Panel Status LEDs LCD keypadProfibus Communication No YesApp Transfer Prim -> Stby No Yes
Internal Memory Size 192 / 440 kb 1 MbApplication Size 768 kb / 2 Mb 7 Mb
Network connections 2 /4 6Remote I/O Racks No 31 (RIO)
Remote I/O Ethernet Islands 64 per Network 128 per Network
Schneider Electric 35Automation BU – End User Domain - Americas Business Support
Technical characteristics lead to Market positioningoPremium is optimized for:
● very high availability and high switching performance over short distances
● high availability and non time-critical switching performance over long distances
oQuantum is ideal for:● High availability in big applications with good switching time performance ● High availability with long distance architecture● High availability in continuous process control● Quantum has options not always mandatory in water or infrastructures
Market segmentation Premium or Quantum HSBY?
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Final Comments Launch Site and DMDI
• Much information on launch site – go to Planet, search on “Premium”, select “launch site”.
• Checklist in DMDI
• Marc Lafont will visit from France for a full 2-day training session. Details tbd depending on interest
• Survey
Any questions?
Thanks for joining us!
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