CompactLogix Hot Backup Whitepaper

HOT Backup Redundancy for CompactLogix

White Paper

(For internal use only)

CompactLogix Hot Backup Whitepaper

Contents:

 Overview
 Design Specifications
 Methodology for Hot Backup
 Logic for Hot backup
 Periodic Task
 Main Routine
 Do Inhibit Routine
 Do Un-Inhibit Routine
 Ownership Routine
 HMI Status and Control
CompactLogix Hot Backup Whitepaper

Overview:
This application technique describes how to use ladder logic to switch I/O control to a peer
Logix5000™ controller if a problem prevents the primary controller from controlling the system.
There are no hardware modules to perform this control, so ladder logic controls the redundancy
system. In this configuration, both controllers are live and able to control outputs in the system.
This is not a valid configuration in a Logix5000 system. As a result, ladder logic must inhibit the
output connections in the peer controller so that only one controller can control an output module
at a time.

Design Specifications:

To use this technique, you must be able to tolerate all of the following criteria:
1. A delay of 250 ms…5 seconds can occur before the peer controller gains full control of the
system.
2. Ethernet modules and ports do not swap IP addresses.
3. Controllers and Ethernet adapters must have fixed IP addresses.
4. You must use only 1756 or 1794 I/O modules.
5. The application supports only remote I/O on the Ethernet network.
6. Only 1769-L30ER and 1769-L33ER controllers are supported. CompactLogix™ controllers that
have built-in I/O or support motion control are not supported.
7. The application does not support motion control.
8. A loss of communication to all of the output modules being monitored will cause a
CompactLogix Hot Backup Whitepaper

switchover. In this scenario, all of the outputs are switched over to the new primary
controller.
9. The application does not support a mixed set of output modules where some output modules
are on controller A and the other modules are on controller B.
10. If you mix input and output modules in the same chassis, you must enter logic to inhibit or
uninhibited each output module in the chassis.

Methodology for Hot Backup:

This section will describe about methodology used to implement the hot backup redundancy:
 Two CompactLogix 1769-L30ER are communicating with common FlexIO Rack on
Ethernet I/P.
 The controller who first take ownership of DO modules will become the primary
controller. Only one controller will be primary at a time
 In case of inputs both controllers are owners of input cards and receive live input
updates from remote rack.
 For output there will be only one owner of respective output modules. The other
controller will inhibit its control from output modules.
 Outputs are configured to hold last state so incase the primary controller shift the
output remain Bumpless
 Program is running simultaneously in both controllers and only owner will update the
respective outputs.
 Both controllers are sharing healthy status with each other via produce/consume tags
 In case any fault is detected on primary controller it shifts control to peer controller.
CompactLogix Hot Backup Whitepaper

Logic for Hot Backup:

Periodic Task:
A periodic task is created in Studio 5000 Software called by the period of the task is 15ms and
priority is set to 10. As a result, note the following:
1. The task will execute every 15 ms.
2. Do not configure other tasks to use the same priority as this task. If another task in your
application is already using priority 8, you must change the priority of one of the tasks

The periodic task contains one program which has 5 routines in total. We will discuss about each
program in following section:

Main Routine:
This routine contains the main logic to implement hot backup redundancy of CompactLogix System. The
core purpose of the logic define in this routine is given below:

1. Contains a startup timer, which holds further execution of certain tasks to check
whether the current controller has ownership of output cards or not
2. Once declared that the current controller is owner (Primary) or not. Main routine calls
other sub-routines for exchanging information with partner controller
3. Contains logic to make the controller owner (primary) based on manual command from
HMI or based on fault information received from partner controller
CompactLogix Hot Backup Whitepaper

DO Inhibit Routine:
This routine will be called only when the controller is not primary to close its CIP connection with the
respective output modules.SO that the other controller can take ownership of output modules.

This routine make use of GSV instructions to get module configuration data of all Output modules and
by using SSV instruction it inhibit controller’s connection with Output cards.

The rung in the Inhibit Outputs routine performs these functions:

1. The GSV instruction sets the mode attribute of the module called in the Instance Name
parameter and stores it in the mode member of the tag with the same name as the module.
2. Sets bit 2 of the mode member to indicate that the controller must inhibit its connection to
the module.
3. The SSV instruction sends the new mode value to the mode member of the tag with the
same name as the module, which inhibits that connection.
DO Un-Inhibit Routine:
This routine will be called only when the controller is primary to open its CIP connection with the
respective output modules.SO that the controller can take ownership of output modules.

This routine make use of GSV instructions to get module configuration data of all Output modules and
by using SSV instruction it un-inhibit controller’s connection with Output cards.
CompactLogix Hot Backup Whitepaper

The rung in the Un-inhibit Outputs routine performs the following actions:
1. The GSV gets the mode attribute of the module called in the Instance name parameter and
stores it in the mode member of the tag with the same name as the module.
2. Clears bit 2 of the mode member, which indicates that the controller must un-inhibit its
connection to the module.
3. The SSV sends the new mode value to the mode member of the tag with the same name as
the module, which un-inhibits that connection

Ownership Routine:
This routine checks the status of Output modules and Flex Adaptor using Entry Status Attribute from
GSV. Based on these status values we can analyze whether the module is in fault, running or waiting
condition

Rec_Clk Routine:
This routine make use of consume tags to receive the healthy status of other controller. If the consumer
tag does not update for a certain time period, it will indicate that other controller is on Fault

Send_Clk Routine:
This routine makes use of produce tags to send the healthy status of controller to the partner controller.
Routine make use of two timers i.e. on delay and off delay to send pulse signal via produce tag. If the
controller goes to fault or if there is any communication error, then this signal cannot be read at partner
controller which indicates a fault
CompactLogix Hot Backup Whitepaper

HMI Status and Control:

Red lion HMI is used to monitor and manually control the primary Status of controllers. Blow screen
specify about the status of controllers. The controller which is primary show its status in green color
while the peer one will indicate red color on the HMI. Operator can also select primary controller by
pressing the respective status Indicator.