Configuring a Hot Standby M580 system complete with SimpleRemote I/O Ring Architecture with Rapid Spanning Tree Protocol (RSTP) Service

Objective
A brief overview of required hardware & to establish a Hot Standby M580 system complete with Simple Remote I/O Ring Architecture (1 drop) with Rapid Spanning Tree Protocol (RSTP) service. This document
assumes that you have connected via USB or the default IP from the factory 10.10.x.x. (x.x being the last two octects of the MAC Address converted from Hexidecimal to Decimal) and downloaded 192.168.10.1
into the service port of the ‘A’ primary rack.

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Required Hardware & Software

Unity Pro XL

  • 3- BMEXBP* Ethernet backplanes
  • 2- BMEH58* HSBY M580 Processors
  • 3- BMXCPS* power supplies
  • 2- 490NAC0100 copper SFP connectors
  • 3- power supplies
  • 2- BMENOC0311 Ethernet modules
  • 1- BMECRA31210 EIO adapter
  • 5- 490NTW00002U Ethernet cables (1 cable for HSBY communication link between the CPUS’s, 1 cable
    for RIO main ring between CPU’s, 1 cable for connection from CPU A Ethernet to EIO CRA, 1 cable for connection from EIO CRA to CPU B Ethernet port, 1 cable for connection to the Service Ports on the
    BMEH58* CPU’s).
References
  • Modicon M580 Hot Standby System Planning Guide for Frequently Used Architectures
  • Modicon M580 RIO Modules Installation and Configuration Guide
  • M580 Redundant Configuration Training Manual
  • Unity Pro XL v13.1
  • Images from www.schneider-electric.com

Section 1: Understanding Hot Standby

What is Hot Standby (HSBY)?

HSBY is a system design where the Primary and Secondary system run simultaneously. The data in the Primary is mirrored from the active Primary over to the Secondary so both systems contain identical information on the running process. If abnormal operation occurs in the Primary, the Secondary system
immediately becomes Primary.

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CPU Module Hardware Identification

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  1. LED Display
  2. MAC Address
  3. Mini-B USB
  4. RJ45 Service Ethernet Port
  5. RJ45 Device Ethernet Ports
  6. 1Gbps Synch Link Small Form-factor Pluggable (SFP) *copper or fiber SFP choice*
  7. Product QR Code
  8. X-Bus and Ethernet Connection to backplane
  9. Slot of #optional SD memory#
  10. Locating and Earthing connection to backplane

*Copper link is rated up to 100 meters, Fiber link is rated up to 15 kilometers*

  • 490NAC0100 – copper SFP
  • 490NAC0201 – fiber SFP

#Industrial grade SD memory card formatted for use with the Schneider Electric M580 CPU only#

Data written to the CF card is NOT managed by the M580 redundancy system. Data on this card must be manually managed by the end user. Use a rising edge on system bit %S65 to safely eject the hardware
without data loss.


BMXRMS004GPF - Industrial grade SD memory card

Port Usage

Service Port – This port can be used for diagnosis of the Ethernet ports using port mirroring. This port
may also be used for external tools and devices such as Unity Pro, HMI, SCADA & Distributed I/O devices.


Device Ethernet Ports – These 2 ports may do Distributed I/O(DIO) or Remote I/O(RIO). DIO allows comms with modules or devices using a non-deterministic DIO scanner in the CPU. RIO uses a RIO
scanner in the CPU that allows deterministic I/O exchanges with devices on the RIO network. If using RIO, Rapid Spanning Tree Protocol (RSTP) service is deployed allowing ring communication recovery
within 50 milliseconds. RSTP is bi-directional communications and is also available on eNOC, eNOS NRP etc. Device and drop diagnostics are allowed for either DIO or RIO.


1GBps SFP socket – Used only as a CPU synchronization link.

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M580 HSBY CPU Choices

There are 3 choices of CPU:

  • BMEH582040 – Level 2
  • BMEH584040 - Level 4
  • BMEH586040 – Level 6

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Determining which CPU is A or B
Use the rotary switch on the back of each M580 Hot Standby
CPU to designate the role that the CPU plays in the M580 Hot
Standby configuration.


One of the HSBY CPU must be set to A, one must be set to B.


Another important function of this switch is the Clear for the CPU memory.


To Clear, set the switch to clear, install the CPU on the rack, power up & then power down and set to A or B.

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Racks Used for M580 HSBY
There are 5 varients of the M580 backplane that may be used with HSBY, the 4,6, 8, 10 & 12 slot. The 4, 8 & 12 slot are single power supply backplanes. The 6 & 10 slot backplanes are dual power supply
backplanes:

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BMEXBP0400 – 4 slot backplane, each slot is both xBUS and Ethernet compatible. Single power supply.

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BMEXBP0602 – 6 slot backplane , each slot is both xBUS and Ethernet compatible. Dual Power supplies. 

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BMEXBP0800 - 8 slot backplane, each slot is both xBUS and Ethernet compatible. Single Power Supply.

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BMEXBP1002 – 10 slot backplane, 8 slots are both xBUS and Ethernet
compatible. 2 available slots have Xbus only connections. Dual Power
supplies.

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BMEXBP1200 - 12 slot backplane, 8 of the slots are both xBUS and Ethernet compatible. 4 of the available slots have xBus only connections. Single power supply.

If using the Dual Power Supply Backplane, you must choose a X80 redundant Power Supplies part number:

  • BMXCPS3522 – Redundant 125VDC Power Supply
  • BMXCPS4002 – Redundant AC Power Supply
  • BMXCPS4022 – Redundant 24-48VDC Power Supply

For a more information on the capabilities of the redundant power supplies see the Redundant Power Supply Management Functions manual. 

Section 2: Software Configuration of the HSBY Racks

With the Unity Pro XL open, choose the File menu and choose New.

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Choose your BMEH58* HSBY CPU & the rack that you will be using below. Click on OK.

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You will now see a populated Project Browser. Double click on Configuration.

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You will see a Graphical representation of your M580 HSBY rack.

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Double click on the one of the 3 Ethernet ports on the graphical representation of your HSBY CPU.

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You are then presented with the EIO configuration window. Choose the IP Config tab.

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An M580 HSBY requires that the user configure 3 IP addresses. Unity Pro XL will also create one additional 4th IP address

The Unity Pro XL will assign a Main IP Address & Main IP Address +1 default IP address (+1 in the fourth octet – not editable). The purpose is to provide seamless communication transitions on Hot Standby CPU switchovers.
  • IP Address A must be configured. This is the IPV4 address for the CPU with the rear switch set to A as shown earlier in this document.
  • IP Address B must be configured. This is the IPV4 address for the CPU with the rear switch set to B as shown earlier in this document.
  • Subnetwork Mask will need to be populated to identify the network address and the subnetwork portion of the IP address.
  • Gateway Address is the default gateway for messages to be transmitted to other networks.

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Choose the Security tab.

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Click the Unlock Security button to disable Access Control, enable FTP, enable TFTP, enable HTTP, enable DHCP/BOOTP, enable SNMP & enable EIP. Make note to re-enable Enforce Security before
deploying the system.

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Look under the PLC dropdown for the Validate check box and Validate the changes.

Next, we will set up the HSBY setup parameters.

Double click on the CPU module (not on the Ethernet ports).

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Choose the Hot Standby tab. Select the Allow Logic Mismatch. This is the maximum number of online build changes from 0...50 that can be performed on the primary PAC. When this number of online build
changes has been reached, you need to transfer the application from the primary to the standby to be able to make additional online build changes. Default = 20.


Choose the Behavior of the CPU in Wait and Standby mode. Specify the sections of the MAST task the standby PAC executes in Wait state. Choices are All Sections (default), First Section & No Section at all. Choose All Sections.

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Validate your changes, go to the Build dropdown and Build the application. Go to File and Save the application.

Section 3: Software Configuration of the RIO Drop

In the Project Browser, double click on the EIO Bus selection.

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Double click on the Bus place holder.

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Select the correct Ethernet remote drop and Drop End Communicator and click OK.

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You will see that the EIO drop has been created in the EIO Bus screen.

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Double click on one of the slots to the left of the BMECRA31210 to add a power supply to the EIO rack.

Choose the correct power supply and click on OK.

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Back in the PLC BUS graphic, double click on the one of the 3 Ethernet ports on the graphical representation of your HSBY CPU.

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Click on the IP Config tab. Click on the Update CRA IP Address Configuration to open up the Ethernet Network Manager.

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Note that an IP address has been assigned to the BMECRA31210. Also take note that the device name is set to BMECRA_001.

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Next, look at the BMECRA31210 and notice 2 switches on the front of the module. IMPORTANT – this switch is not configuring an octet but rather a Device Name. Ensure that power is not applied to the
rack. Using a small flat tipped screwdriver, manipulate the switch to match the number in the network name. The values you set are applied during a power cycle.

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Validate your changes, go to the Build dropdown and Build the
application.

Go to File and Save the application.

Section 4: Connect and Download via Ethernet

We need to first configure the hardwired port of your PC to connect to the Service Ports of your M580’s. 

Click on your Start button and type “View Network Connections”.

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The "view network connections"  window will open up.

Double click on your Local Area Connection.

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You will be presented with the Local Area Connection Status screen, click on Properties.

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You will be presented with the LAN Area Connection Properties screen, double click on Internet Protocol Version 4 (TCP/IPv4).

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You will be presented with the Internet Protocol Version 4 (TCP/IPv4) Properties screen. Configure theIP address of the PC to be 192.168.10.XX (where x is not used by the HSBY CPU or control system). Click OK.

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In Unity Pro XL, go to the PLC menu and Set Address.

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The Set Address screen will be active, ensure that the check mark is next to the PLC header. Set the IP address to the the Service Port of the HSBY CPU that you are connected to. Click Test Connection.

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Upon successful connection, you are informed. Click on OK.

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In Unity Pro XL, go to the PLC menu and Connect.

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In Unity Pro XL, go to the PLC menu and choose Transfer Project to PLC. Note the option to Transfer Project from the Primary to StandBy PLC.

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Choose to Transfer the project to the controller.

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Pay attention to the bottom bar in the Unity Pro XL.

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Also monitor the status led’s on the HSBY CPU’s & CRA31210.

Section 5: Other Items to Highlight

When theM580 redundnat CPU’s are configured, 2 Derived Data Types (DDT) are automatically added to the application so that you may easily obtain status and diagnostics about the redundancy system. There should have been one added for the BMECRA31210_001 as well.
BMEP58_ECPU_EXT:

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ECPU_HSBY_1:

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EIO2_d1_r0_s0_ECRA31210:

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EIO2_d1_r0_s0_ECRA31210:

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You can Run/Stop, Swap Primary/Standby etc. from the Unity Pro XL. Double click on the CPU module (not on the Ethernet ports).

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Left click on the Animation tab.

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For further information or Technical Support on Schneider Electric control products, you can contact 1-
888-266-8705 or online www.schneider-electric.ca or Schneider Portal

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