Emerson PACSystems RX3i User manual

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

User Manual Contents
GFK-2409B Oct 2019
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Contents
Chapter 1: Introduction ..........................................................1
1.1 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...................................................7
2.1 Architecture ........................................................................................................ 7
2.2 Software Components......................................................................................... 9
2.3 Hot Standby Redundancy Operation.................................................................. 10
2.4 Failover Time..................................................................................................... 10
2.5 Synchronized Data Transfers ............................................................................. 11
2.6I/O Bus Topologies............................................................................................. 11
2.7 Genius Dual Bus I/O Capacity ............................................................................. 11
2.8 Selecting the I/O................................................................................................ 12
2.9 Demo Mode Operation...................................................................................... 13
Chapter 3: Building a Max-ON RX3i Hot Standby Application 14
3.1 Max-ON RX3i Project ......................................................................................... 14
3.2 Project Workflow............................................................................................... 14
Chapter 4: The Max-ON RX3i Configuration Utility ................21
4.1 Max-ON RX3i Projects........................................................................................ 21
4.2 Working with the Max-ON RX3i Configuration Utility ......................................... 26
4.2.1 Adding Genius I/O Devices ...................................................................... 35
4.2.2 Project Information ................................................................................. 44
4.2.3 User Defined Alarms................................................................................ 45
Chapter 5: Programming Considerations ..............................47
5.1 Advanced Topics ............................................................................................... 59
Chapter 6: Configuring the Hot Standby Redundancy CPUs...70
6.1 Configuring PLC A.............................................................................................. 71
6.2 Configuring PLC B.............................................................................................. 80

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Contents ii
Chapter 7: Configuring the I/O Devices .................................86
7.1 Configuring the Ethernet I/O Devices................................................................. 86
7.2 Configuring the Genius I/O Devices ................................................................... 87
Chapter 8: Diagnostic Tools ................................................100
8.1 Step 1 - Create a Max-ON RX3i Diagnostic Tool View Project............................ 100
8.2 Step 2 –Configure Ethernet Connections to the PLCs ...................................... 102
8.3 Step 3 –Use the Max-ON RX3i Diagnostic Tool ................................................ 103
8.4 System Status.................................................................................................. 104
8.5 Alarms............................................................................................................. 105
8.6 Project Information ......................................................................................... 106
8.7 Authorization .................................................................................................. 107
A-1 General Max-ON RX3i Considerations .............................................................. 108
A-2 Improving Ethernet Sync Efficiency Using PLC Sweep Mode ............................. 108
A-3 Hot-Swapping IC693/IC694BEM331 Modules .................................................. 110
D-1 Updating an Existing Max-ON RX3i Application ................................................ 120
D-1.1 Backup the Application ......................................................................... 120
D-1.2 Updating from Releases Prior to 3.14 .................................................... 122
D-1.3 Add EGD Exchanges to PLC A................................................................. 123
D-1.4 Add EGD Exchanges to PLC B ................................................................. 129
D-1.5 Update the Max-ON Drivers................................................................... 135

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Warning, Caution Notes as Used in this Publication
Warning
Warning notices are used in this publication to emphasize that hazardous voltages, currents,
temperatures, or other conditions that could cause personal injury to exist in this equipment or
may be associated with its use.
In situations where inattention could cause either personal injury or damage to equipment, a
Warning notice is used.
Caution
Caution notices are used where equipment might be damaged if care is not taken.
Notes: Notes merely call attention to information that is especially significant to understanding and operating the equipment.
These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible
contingency to be met during installation, operation, and maintenance. The information is supplied for informational
purposes only, and Emerson makes no warranty as to the accuracy of the information included herein. Changes,
modifications, and/or improvements to equipment and specifications are made periodically and these changes may or may
not be reflected herein. It is understood that Emerson may make changes, modifications, or improvements to the
equipment referenced herein or to the document itself at any time. 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.
Emerson provides the following document and the information included therein as-is and without warranty of any kind,
expressed or implied, including but not limited to any implied statutory warranty of merchantability or fitness for particular
purpose.

User Manual Chapter 1
GFK-2409B Oct 2019
Introduction 1
Chapter 1: Introduction
Thank you for choosing Max-ON RX3i Hot Standby Redundancy software and Emerson
PACSystems™ RX3i controllers to implement your critical control project.
Max-ON RX3i Software consists of several software components, some of which execute in
a pair of Hot Standby PACSystems Max-ON RX3i Controllers, and some of which execute
upon your programming workstation.
The PACSystems controller-based software consists of a set of application blocks that
perform the Redundancy portion of the Hot Standby application. These application blocks
are provided as part of a PAC Machine Edition Project that is the starting point of your
redundant automation application. Using Emerson’s PAC Logic Developer PLC
programming software, you add your application logic to this project, and then store the
overall project to each of the Hot Standby controllers.
The Max-ON RX3i Configuration Utility, which is launched from the Logic Developer PLC
Project, provides a utility to allow the control system designer to customize the functionality
of the redundant system.
A PAC View Max-ON RX3i Project is also provided to monitor the status of the Redundant
System and to display diagnostic information.
With the Max-ON RX3i LD Project , you can:
•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.
With the Max-ON RX3i Configuration Utility software, you can:
•View and Modify the parameters of the Hot Standby Redundancy system:
—Redundant System Parameters
—Synchronization Data Groups
—Synchronization Network Interface Parameters
—Genius I/O Bus definitions
With the Max-ON RX3i View Project, you can:
•Establish a communication link to the Hot Standby CPUs to:
—Monitor system-level alarms in real-time
—Monitor performance characteristics in real-time
—Display information about the Redundant system: Max-ON driver version, CPU
modules

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Introduction 2
1.1 Installing Max-ON RX3i Software
1.1.1 System Requirements
Max-ON RX3i Software may be installed on a PC that has the minimum requirements shown
below:
•1 GHz Pentium class processor
•256 MB RAM or more
•Windows XP Professional Service Pack 2, Windows 2000 Professional Service
•Pack 4
•50 MB of free disk space
Note Max-ON RX3i Software requires Logic Developer PLC Professional Edition Release 5.80 LD PLC
SIM 1 or later.
1.1.2 To Install Max-ON RX3i Software
1. Make sure that you have installed PAC Machine Edition release 5.8 SIM 1 or later.
This is required to configure and program the Max-ON RX3i CPU.
2. It is recommended that you close all applications including virus checking, Internet
Explorer, and HMI software that might be running in the background. You may
need to check the task manager to determine if other applications are running. As
a further precaution, it is also recommended that you re-boot the PC to make sure
components that Max-ON RX3i Configuration Utility needs to update are not
running during the installation process.
3. Put the Max-ON RX3i Software CD in CD-ROM Drive.
4. Select the CD drive from Windows Explorer.
5. Double click Setup.exe.
6. Follow the user prompts to complete the installation.
1.1.3 Uninstalling Max-ON RX3i Software
Max-ON RX3i Software can be uninstalled only from the computer upon which it is installed.
It cannot be uninstalled over a network. You can uninstall Max-ON RX3i Software from the
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. Choose Uninstall from the Start Menu or the Control Panel.
2. A dialog box appears asking if you are sure you want to uninstall.
3. Confirm the Uninstall.

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Introduction 3
•All files relating to Max-ON RX3i Software will be removed from the hard drive. Any
files used by both Max-ON RX3i Configuration Utility and another application will be
left on the system.
•All registry entries relating to Max-ON RX3i Software will be removed from the
systems registry.
•Icons for Max-ON RX3i Software will be removed from the Start Menu.
•Any data you created (for example, Project that you have created) will be left on the
system.
Note: You may also uninstall Max-ON RX3i Software by choosing Add/Remove Programs from the
Control Panel, then selecting Max-ON RX3i Tools
1.1.4 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. It is
launched by double-clicking on the Max-ON RX3i configuration file (config.mx3) located in
the PAC Logic Developer PLC project.
The default Max-ON RX3i Hot Standby Redundancy application project, named Max-ON
RX3i LD Project vx_yy.zip, is located in the Redundancy LD directory. This project must be
brought into your PAC Machine Edition development environment using PAC Machine
Edition’s File > Restore Project… menu.
A PAC View Diagnostic project is in the Diagnostics VIEW directory. When it is active, this
diagnostic utility displays key information regarding the operation and state of the
redundant CPU pair. This project must also be brought into your PAC Machine Edition
development environment using PAC Machine Edition’s File > Restore Project… menu.

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Introduction 4
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.
Figure 2:
Using the File menu, click on Restore Project...
Figure 3:
Navigate to the PAC Components directory, then to the Redundant LD directory. Make
certain that the selection for Files of Type has been set to PAC Machine Edition (*.zip).
Figure 4:

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Introduction 5
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.
Launching the Max-ON RX3i Configuration Utility
The Max-ON RX3i Configuration Utility is launched from the Machine Edition project. Open
the project that you restored in the previous section. There are three targets in the project:
Figure 6:
•PLC_A_HW –This target contains the hardware configuration for PLC A. It must be
edited to reflect the hardware settings and components in your system. Then it must
be downloaded to PLC A (only).
• PLC_B_HW –This target contains the hardware configuration for PLC B. It must be
edited to reflect the hardware settings and components in your system. It will be
very similar to PLC A hardware configuration, except for certain items such IP
addresses, Genius bus controller settings, etc. In a similar fashion, this configuration
must be downloaded to PLC B (only).

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Introduction 6
•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. Note that the download consists
of the PLC Logic only, the Hardware Configuration option must be unchecked.
You navigate to the Max-ON RX3i Configuration Utility by following these steps:
1. Select the target PLC_COMMON_CODE.
2. Expand the tree structure so that the Supplemental Files folder named Documentation
Files is visible
Figure 7:
3. Double-click on Documentation Files. This will launch Windows Explorer for this
directory.
4. Click on the Max-ON Project directory to display its contents. The Explorer window
will be like what is shown below.
Figure 8:
5. Double-click on the Max-ON RX3i Configuration file named config.mx3. This
launches the Max-ON RX3i Configuration Utility.
6. You may now examine and edit the parameters of the Max-ON RX3i redundant
system.