SBC PCD3.M6880 User manual

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

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
PCD2.M4x60
Contents
0-1
0
0 Content
0.1 Document History .................................................................................. 0-3
0.2 Trademarks ........................................................................................... 0-3
1 Standby System Overview
1.1 Introduction ........................................................................................... 1-1
1.2 Terminology ........................................................................................... 1-3
1.3 Designing the System ........................................................................... 1-5
1.4 Order details .......................................................................................... 1-6
1.5 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
1.6 PCD3.T668 Standby RIO ...................................................................... 1-10
1.6.1 Architecture of the PCD3.T668 ............................................................. 1-10
1.6.2 Technical Data ....................................................................................... 1-11
2 Conguration and Programming
2.1 Creating a Standby System Project in PG5 .......................................... 2-1
2.2 PG5 Project Manager View ................................................................... 2-5
2.3 Process Data Synchronization .............................................................. 2-6
2.4 Media Exchange ................................................................................... 2-8
 ......................................................................................... 2-11
 ............................................ 2-11
 .......................................................... 2-14
 ................................................... 2-16
2.5.4 Error and Warning Messages ................................................................ 2-16
 ................................................. 2-19
2.6 Programming ......................................................................................... 2-20
2.6.1 CPU0 Control Program ......................................................................... 2-20
2.6.1.1 Using the same program in the Primary and Secondary devices ......... 2-20
2.6.2 CPU1 Redundant Program ................................................................... 2-24
2.6.2.1 Going Online to Active CPU1 ................................................................ 2-25
2.6.3 Switchover XOB 31 ............................................................................... 2-26
2.6.4 System Symbols ................................................................................... 2-26
2.6.5 Download Programs to Standby System dialog box ............................. 2-27
3 Diagnostics
3.1 Halt and History Messages ................................................................... 3-1
3.2 Diagnostic Tags ..................................................................................... 3-2
3.3 Diagnostic Flags .................................................................................... 3-3
3.4 Diagnostic Registers ............................................................................. 3-3
3.5 Ether-SIO Diagnostics Extension .......................................................... 3-4

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
PCD2.M4x60
Contents
0-2
0
4 Technical Information
4.1 Data Synchronization and Switchover (Synchronous) .......................... 4-1
4.2 Data Synchronization and Switchover (Asynchronous) ........................ 4-1
4.3 LED States ............................................................................................ 4-1
4.4 State Machine ....................................................................................... 4-2
4.5 Troubleshooting ..................................................................................... 4-2
A Annex
A.1 Icons ......................................................................................................A-1
A.2 Instructions for connecting Saia-PCD®controllers to the internet .........A-1
A.2 Contact ..................................................................................................A-2

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
PCD2.M4x60
Contents
0-3
0
0.1 Document History
Version Changes Published Comments
ENG01 2015-11-27
2016-03-11
2017-04-03
2015-11-27
2016-03-16
2017-04-03
First edition
PCD3.Fxxx --> 26-857
new footer
ENG02 2017-04-26 2017-04-26 Ch3.1 - more possible failures listed
0.2 Trademarks
Saia PCD®is a registered trademark of Saia-Burgess Controls AG.
Technical changes are subject to the state of technology.
Saia-Burgess Controls AG, 2017. © All rights reserved.
Published in Switzerland

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
Introduction
Standby System Overview
1-1
1
1 Standby System Overview
1.1 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.
Simple system architecture to reduce costs.
Standby processors with shared Ethernet Remote I/Os
avoids the duplication of the inputs/outputs and the sensors/actuators.
Programmable remote I/Os create intelligent decentralized nodes to provide
additional reliability.
The network uses standard Ethernet components, and can run over a standard
Ethernet TCP/IP network along with other services.
Easy engineering and commissioning, using the PG5 Project Manager to auto-
matically generate the project.
Uninterrupted switching from Standby to Active device.
Standby controllers contain two processors. One processor runs the redundant
program and monitors the active PCD. The second independent processor runs


 

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
Introduction
Standby System Overview
1-2
1
Ethernet
SCADA 1 SCADA 2




IPnetwork
with bre optic ring
SecondaryPrimary
Process I/O Process I/O
SCADA system
Standby Controllers
PCD3.M6880
Smart RIOs
PCD3.T668
Typical layout of a redundancy system with two PCD3.M6880 Standby devices and PCD3.T668 Ethernet Smart
RIOs.

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
Terminology
Standby System Overview
1-3
1
1.2 Terminology
The following denitions 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

Secondary PCD The PCD which becomes the standby device on power
up, and only takes over active control in the event of
a fault on the active device.
Active PCD The PCD whose CPU1 is in Active Mode, running the
redundant program and controlling the inputs/outputs
(PCD3.T668 RIOs).
Standby PCD The PCD whose CPU1 is in Standby mode. It does not
run the redundant program and the outputs
(PCD3.T668 RIOs) are not controlled by this device.
Main CPU CPU0 of the Primary or the Secondary PCD, which runs
the non-redundant program. This program may be
󰀨
Redundant CPU CPU1 of the Primary or Secondary PCD, which contains
the Redundant program. This program must be the
same on the primary and Secondary devices. This CPU
is either in Active mode and running the Redundant
program, or in Standby mode and monitoring the Active
PCD.

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
Terminology
Standby System Overview
1-4
1
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. The two PCDs (primary and
secondary) monitor each other. If the active PCD fails, the standby PCD takes
over processing and control of the connected RIO stations. The process image
(I/O) and the internal PCD media (F, R, T, C, DB) - the synchronization data - are
continuously transferred from the active PCD to the standby PCD via the Ethernet
connection. This ensures uninterrupted switching from the active to the standby
PCD.
The Redundant CPU1 has two inde-
pendent Ethernet interfaces. The ETH
2.× interface is reserved exclusively for
operating the PCD3.T668 RIO stations.
The PCDs also synchronize their pro-
cess data via the same interface. For
security reasons, we recommend set-
ting up this network as a ring structure

third-party providers. We have had good
experiences with the industrial Ethernet
switches from Hirschmann.
Ethernet 2
(2 port switch)
The ETH 1 interface on CPU0 is avail-
able for connecting and operating other
systems and devices. For example,
SCADA systems can be connected via
this interface. SBC does not provide its
own SCADA system for redundant auto-
mation solutions, but almost any system
can be used. A single SCADA system,
or an additional redundant SCADA
system can be used if it supports re-
dundant controllers. The PCD3. M6880
controllers provide detailed status and
diagnostic information which can be
evaluated by the SCADA systems.
Ethernet 1

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
Designing the System
Standby System Overview
1-5
1
1.3 Designing the System
Redundant automation solutions can be achieved with various network topologies.
Physically separating the management network (SCADA systems) and the
network for the remote I/Os is recommended. We also recommend setting up


availability and thus the system reliability. Standard devices from third-party
providers can be used for the network components (switches). We have had good
experiences with the switches (RS30) from Hirschmann. However, the networks
can also be set up with standard components in a star structure. A shared physical
network for the remote I/Os and management systems is also possible, but
availability of the system will be reduced accordingly.
Ethernet
SCADA 1 SCADA 2




Network redundancy
with ber optical ring
SecondaryPrimary
Process I/OProcess I/O
Standby Controller
PCD3.M6880
SCADA-System
Smart RIOs
PCD3.T668
Ethernet
Ethernet
SCADA 1 SCADA 2
SecondaryPrimary
Process I/OProcess I/O
Standby Controller
PCD3.M6880
Smart RIOs
PCD3.T668
SCADA-System
Recommended network topology with physi-

Physically separate networks in a star topology
with standard components
Ethernet
Standby CPU
PCD3.M6880
Standby CPU
PCD3.M6880
SCADA 1 SCADA 2
SecondaryPrimary
Process I/OProcess I/O
SCADA-System
Smart RIOs
PCD3.T668
Shared physical network in a star topology with
standard components

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
Order details
Standby System Overview
1-6
1
1.4 Order details
PCD3.M6880 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

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
PCD3.M6880 Standby Controller
Standby System Overview
1-7
1
1.5 PCD3.M6880 Standby Controller
1.5.1 Architecture of the PCD3.M6880
The PCD3.M6880 standby controller has two independent processors (CPU0 and
CPU1). Both processors have their own independent PCD media (F, R, T, C, DB/
TX).
The redundant CPU1 runs the redundant user program and controls the shared
inputs/outputs of the PCD3.T668 remote I/Os. The redundant programs in the
primary and secondary PCD3.M6880s are identical. During normal operation,
only the active PCD runs the redundant program. CPU1‘s internal used PCD
media (F, R, T, C, DB/TX) are transferred from the active to the standby PCD via
the Ethernet interface 2 (ETH2.x). In the event of a fault, the standby PCD takes
over operation without interruption, and runs the redundant program using the last
process image from the active PCD.
󰀨
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. External systems and devices
(SCADA systems, web browsers and other external devices) communicate only
with CPU0. CPU0‘s internal PCD media (F, R, T, C, DB) are not synchronized
between the active and standby PCD.
CPU1‘s program cannot directly access the local IOs or CPU0‘s media (and vice
versa). Data is exchanged between CPU0 and CPU1 using a data exchange


program cycle.
Eth 2.2 Eth 2.1 USB Eth1
Ethernet RIO
PCD3.T668
SCADA and/or
other systems
Standby controller PCD3.M6880
Redundant
(CPU1)
4Non Red.
Program
IO
Flash
BACnet
LON
Com
3Red.
Program
1Media
2S-Bus
Main (CPU0)
PCD3.M6880
1 Data Media Transfer (Exchange Range or/and CSF/FBox)
󰀨
3 Redundant program on CPU1 runs only if active. Same program on both PCDs.
󰀨

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
PCD3.M6880 Standby Controller
Standby System Overview
1-8
1
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 64 ––
I/O expansion connection for PCD3.C module holder Yes ––
Processing time [µs] bit operation
word operation
0.1…0.8 µs
0.3 µs
Real time clock (RTC) Yes
On-Board memory
Program memory, DB/TEXT (Flash) 2 MByte
User memory, DB/TEXT (RAM) 1 MByte 128 KByte
 128 MByte
 128 MByte ––
PCD media:
Register
Flag
DB/TEXT
16384
16384
8192
16384
16384
8192
On-Board interfaces
USB 1.1 Yes No
Ethernet 10/100 Mbit/s, full-duplex, auto-sensing/auto-crossing ETH1 ETH2.x (2 port switch)
RS-485 on terminal block (Port 2) or

up to 115 kbit/s
up to 187.5 kbit/s ––
Optional communication interfaces
I/O slot 0*:
PCD3.F1xx modules for RS-232, RS-422, RS-485
and Belimo MP-Bus
Yes No
I/O slot 0…3 up to 4 modules or 8 interfaces*:
PCD3.F2xx modules for RS-232, RS-422, RS-485, BACnet®MS/
TP, Belimo MP-Bus, DALI and M-Bus
Yes No
Other features
Communication protocols/systems
(BACnet, Modbus, ®, DALI, M-Bus…)
As PCD3.M6860
without 2nd Ethernet No
Automation server
 Yes No
Connection and operation of PCD3.T668 remote I/O
Number of supported RIO stations
No
––
Yes
64
Connection and operation of PCD3.T665/T666 remote I/O
Number of supported RIO stations
Yes
64
No
––
Access to the I/O slots in the basic housing as well as to the
PCD3.Cxxx I/O terminal bases Yes No
*see manual 26-857

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
PCD3.M6880 Standby Controller
Standby System Overview
1-9
1
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“

Timeout” can be adjusted between 100…500 ms. By this the max. switchover
latency is <100…500 ms.
The ACTIVE PCD‘s state is not RUN or STOP (stops sending Keep Alive).
A manual switchover command is executed. This is only possible if the Primary
device does not have priority, the „Primary device has priority“ option must be
„No“.




Data Synchronization and Supervision (Keep Alive)
Data Synchronisation and Program Cycle:
The used PCD medias (R, F, T/C, DB/TX) in the redundant CPU1 are cyclically
synchronized between the active and the standby PCD. The synchronization time
for all PCD media is normally less than 200 ms. This time is reduced accordingly if
only a part of the PCD media is used. The total program cycle time is calculated as
follows:
Total cycle time = program execution time + data synchronization time
The max. value for a large application can be calculated as follows: 100 ms +
200 ms = 300 ms max.
For smaller applications where less PCD media are used the cycle time is reduced
correspondingly.

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
PCD3.T668 Standby RIO
Standby System Overview
1-10
1
1.6 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.
T665 and PCD3.T666 standard remote I/Os cannot be used with Standby
Controllers.
Can be used as a simple local I/O station or an intelligent programmable
I/O station
Can be programmed with the PG5. Important or timecritical tasks can be
processed directly in the RIO
The RIO‘s user programs are managed centrally by the Smart RIO Manager
(PCD) and downloaded to the RIOs automatically
 󰀩

Cross-communication with other PCD systems using Ether-S-Bus (FBoxes)
Intelligent communication modules (e.g. M-Bus, DALI) are supported
Other communication protocols (e.g. Modbus) via Ethernet TCP/IP and
also by the onboard RS-485 interface
Integrated Web Server

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
PCD3.T668 Standby RIO
Standby System Overview
1-11
1
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 128
Protocol for data transfer Ether-S-IO
Ethernet connection 10/100 Mbit/s, full-duplex, auto-sensing, auto-crossing
Default IP conguration IP address: 192.168.10.100
Subnet mask: 255.255.255.0
Default gateway: 0.0.0.0
USB port for conguration and diagnostics yes
Program memory 128 kByte
Web server for conguration and diagnostics yes
Web server for user pages yes
On-Board le system for web pages and data 512 kByte
BACnet® or LonWorks®no
On-Board interrupt inputs 2
On-Board RS-485 interface yes
Special modules for I/O-slot 0 only* PCD3.F1xx
for I/O-slots 0…3*
(up to 4 modules)
PCD3.H1xx counter
PCD3.F26x DALI
PCD3.F27x M-Bus
S-Web alarming/trending no
Watchdog no
Real-time clock no
Software clock (not battery-powered) yes, synchronized by the Manager
Battery no
*see manual 26-857

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
Creating a Standby System Project in PG5
Diagnostic
2-1
2
2 Conguration and Programming
2.1 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),

CPUs.
1. Create a new Project
Use Project Manager’s “Project / New Project” command to create a new project.
Check the “Create Device” option.
A single PG5 project can contain one standby system (one primary and one
secondary device). If you have more than one standby system on the same
network, then you must create a new PG5 project for each standby system.
If you are using Ether-S-Bus to communicate between the PCDs of two or more
standby systems on the same network, then you can use the Export and Import
features of the “TCP/IP Settings Table” window to transfer the settings between the
projects.

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
Creating a Standby System Project in PG5
Diagnostic
2-2
2
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” by default, but you can rename it if you like. A standby
project contains 3 devices, by default these are named “1-Primary”, “2-Secondary”

order of the devices in the Project Tree. The devices can also be renamed later.

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
Creating a Standby System Project in PG5
Diagnostic
2-3
2
3. Congure the standby system
When OK is pressed to create the device, Project Manager creates the primary
device, then displays the  dialog box with the default


CPU0 and CPU1 on the Primary and Secondary devices. These media are also
transferred between the devices, see Media Exchange.
According to the application, you may want to use separate “to” and “from”


ToRedSymbolsPrimary.sy5, ToRedSymbolsSecondary.sy5 and FromRedSymbols.
sy5.
You can leave the settings as their defaults, or change the device names or


Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
Creating a Standby System Project in PG5
Diagnostic
2-4
2
defaults is good for starting the project.
See the  dialog box for more details.

If you use Project Manager to rename or delete one of the standby devices or

modify the names there too, Project Manager will not do this automatically. You will
see a 
4. Create the Secondary and Redundant devices

do not exist, and will ask if you want to create them:



window, see .



5. Congure and download the Device Conguration to the Primary and Sec-
ondary devices

Set the S-Bus station number, usually Primary=0 , Secondary=1. Enter the IP
addresses of each device in the “Onboard Communications - Ethernet” slot.

“Onboard Communications - Ethernet” slot, and enter the same the IP Addresses
for the Primary and Secondary devices, see .

devices, see .

Saia-Burgess Controls AG
User Manual Standby System │Document 27-645 │Edition ENG 02 │2017-04-26
PG5 Project Manager View
Diagnostic
2-5
2
2.2 PG5 Project Manager View

“Project Tree”. If the Redundant device connects to programmed RIOs, you will
also see the RIOs in the Project Tree.
Media Exchange.





