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REDUNDANCY
GENERAL INFORMATION
The series 3332 Redundancy System uses dual processors that communicate with the same
physical I/O. One processor is on line, while the other functions as a "hot" backup. A
Switchover Panel included in the system provides arbitration between the two processors.
Should the Switchover Panel detect a failure in the on-line unit, it will switch to the backup
unit without interrupting control and communication functions.
Product Description
A Series 3332 Redundant System contains a Redundancy Switchover Panel (RSP) and two
Redundant Distributed Process Controllers (RDPC). The RSP is shown in Figure 3K-1,
while a RDPC is shown in Figure 3K-2. One of the RDPCs functions as the on-line unit, and
the other as the backup unit.
The Series 3332 Redundancy System provides redundancy for communication ports A
through D. It does not include any on-board I/O facilities. It can serve as a data
concentrator that provides communications for a local area network, or as a distributed
controller that communicates with remote I/O devices. In the latter application, it can
communicate with several Series 3331 RIO Units placed at one or more locations.
During operation, the on-line RDPC executes the ACCOL program load and performs
control and communication functions. It accepts incoming data, performs decision-making
tasks, and outputs processed data over the four communication channels (A-D). It also
continuously up-dates the backup unit via a dedicated communication channel.
The RDPC uses an Enhanced Communication Engine Board (ECE Board) for the second
communication slot (see Figure 3K-6). The ECE differs from the standard version described
in Section 3C in that it includes a Redundancy Channel Board assembly. The Redundancy
Channel Board contains the communication channel that is used to update the backup unit.
The standard Communication Engine Board (CE Board) is always furnished in the first
communication slot of the RDPC. This board can have an optional modem assembled to it as
shown in Figure 3K-6. The modem provides asynchronous communications over phone lines
or other communication media as required. The use of the ECE Board for redundancy
precludes the use of the modem for ports C or D.
The redundancy system requires Rev. 5.2 (minimum) ACCOL software. Earlier versions of
soft-ware are not suitable for this application.
Basic Overview
Figures 3K-3 and 3K-4 show a block diagrams of 3332 Redundant Systems. Both RDPCs
used in these setups must be models with identical options. Each RDPC must also operate
from separate +24 Vdc supply sources to provide added security against the failure of a
signal supply. Note in the illustration that the +24 Vdc power supplies of Unit A and B are
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also wired to the RSP. This dual supply arrangement ensures that the operation of the RSP
will not be affected by a failure of either supply.
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Figure 3K-3 - Block Diagram of 186-Based CPU Redundant System
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The RSP uses triple redundant logic with voting hardware to implement switching from the
on-line unit to the backup unit. Two of three logic outputs must be TRUE in order to initiate
a switchover. This strategy minimizes the chance that certain types of defects might inhibit
a switchover.
The RSP monitors the Watchdog output of each RDPC. This output, which is labeled
ATRAN, is available as an open collector output at the wiring terminals of each DPC (in
power section). Should this signal or the power supply of the on-line unit fail, the RSP will
switch to the backup unit. A manual transfer back to the failed unit is inhibited until that
unit is repaired.
The Redundant Switchover Panel (RSP) and the Redundant Distributed Process Controller
(RDPC) units are intended for rack or panel installations. The RSP is typically installed
between or near the two units. The mounting procedures for both the RSP and RDPC are
the same as those described for the Data Concentrator in Section 2 - Installation.
CABLE CONNECTIONS
Figures 3K-5 and 3K-6 show the location of the cable receptacles on the RSP and RDPC
respectively. The actual connections between these assemblies are shown in the schematics
of Figures 3K-7 and 3K-8. In general, communication connectors J1A to J5A of the RSP
plug into ports A through D2 of Unit A, while J1B to J5B plug into the corresponding ports
of Unit B. RSP connectors P1 and P2 plug into mating receptacles on the Redundancy
Channel Board of Units A and B. And finally, RSP connectors J1C to J5C mate with the
outside communication lines representing ports A through D2 respectively.
The cables for ports A through D that interconnect the RSP and RDPC units will have a dif-
ferent connector on each end. This occurs because the RSP provides nine-pin receptacles
while the RDPCs provide 15-pin receptacles. Details for wiring the nine-pin RSP connectors
are discussed herein; those for the 15-pin RDPC connectors are described in "Appendix CO -
Communication Ports."
The RSP uses nine-pin female receptacles for communication ports A through D2. The
mating connectors used for this application have two-piece shrouds that can be assembled to
the connector even after the pin wiring has been soldered in place. The manufacturer's part
numbers are as follows:
Male Connector ......... AMP 747904-2 Split Shroud .............. AMP 206478-1
A port configured for an RS-423 interface is also usable with devices having an RS-232 com-
munication interface. Devices that fall into this category are printers, VDTs, PCs, etc. For
this application the device must be located within 25 feet of the RSP (this interface scheme
is not intended for network communications). Pin layout for RS-423 is shown in Figure 3K-9
while the pin functions are detailed in Table 3K-A.
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Figure 3K-6 - RDPC Unit with Cover Removed
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Figure 3K-8 - 386EX-Based CPU Cable Connection Diagram
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Figure 3K-11 - RS-423 Interface for IBM PC AT or Compatible Computer
Two typical PC interface schemes are shown in Figures 3K-10 and 3K-11. For other types of
PCs, consult the manufacturer's hardware manual.
RSPs used for network communications require a port configured for RS-485. This interface,
which is an enhanced RS-422 interface, is electrically compatible with Series 3335, 3350 and
3380 controllers; however, these models require 15-pin connectors and not the 9-pin type
used here. Prior to wiring up a system of mixed modules, be sure to properly identify all con-
nectors. Refer to the appropriate controller manual for details.
The connector layout for the RS-485 interface is illustrated in Figure 3K-12, while the cor-
responding pin functions are defined in Table 3K-B.
The RSP units contain a Redundancy Switchover Board and an LED Board which are
shown in Figure 3K-5. In order to access these boards, it will be necessary to remove the
front cover of the RSP. This procedure is the same as described for Data Concentrators in
Section 2 - Installation.
Switchover Board
Referring to Figure 3K-13, note the location of mode jumpers W2 and W3. Check that both
jumpers are plugged across positions 1 and 2. The alternate application for positions 2 and 3
is not utilized. Using positions 2 and 3 will prevent normal panel operation.
Jumper W1, whose location is also shown in Figure 3K-13, provides two grounding options
to minimize ground loops. When the jumper is plugged into W1, the CGND terminal
(chassis connection) is connected to power common as shown below at the left. When the
jumper is removed, (open circuit), CGND is isolated from power common as shown below at
the right.
LED Board
This board contains LEDs that indicate the status and operating modes of Unit A and B.
These functions are detailed under the topic DESCRIPTION OF RSP OPERATING CON-
TROLS on page 3K-23.
The RDPC units contain a System Interconnect Board, CPU Board, Std. Communication
Engine (CE) Board, optional Modem Board, Enhanced Communication Engine Board, and a
Redundancy Channel Board. The location of these boards is shown in Figure 3K-6.
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In order to access these boards, it will be necessary to remove the front cover of the RDC
units. This procedure is the same as described for Data Concentrators in Section 2 - Instal-
lation.
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Figure 3K-15 - Two Port Enhanced Comm. Board (2PECB)
The SI Board is the same board used with regular DPCs. The field connections and jumper
configurations of this board are described in Section 3A of this manual.
Modem Board
Optional Modem Boards are assembled to the Enhanced Communication Board. Details on
modems are covered in appendices.
The 2-Port Enhanced Communication Board, which plugs into the System Interconnect
Board, provides two independent asynchronous/synchronous serial ports. Configuration is
provided by the switches and jumpers called out in Figure 3K-15 (also see Section 3C).
$ Operating Notes
Switch SW1 sets the configuration for the upper port (A/C), while switch SW3 controls
the configuration of the lower port (B/D). Both SW1 and SW3 are 8-position, in-line
packages. SW1 and SW3 of the 2-Port Enhanced Communication Board function as fol-
lows:
All on-board jumpers (except W15 & W19, that are factory installed) are used in con-
junction with miniature headers having protruding pins. The jumper, that plugs in over
the pins, contains a shorting bar. Both two-pin and three-pin headers are used on the
Enhanced Communication Board. The function of each type is shown below.
* Store this jumper for future use by only plugging one end of the jumper into
the pin header as shown above.
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Figure 3K-16 - Redundancy Channel Board (Assembly of RDPC)
SW1-1 ON SW3-1 ON
SW1-2 to SW1-6 OFF SW3-2 to SW1-6 OFF
SW1-7 to SW1-8 ON SW3-7 to SW3-8 ON
SW1-1 ON SW3-1 ON
SW1-2 ON SW3-2 ON
SW1-3 to SW1-8 OFF SW3-3 to SW3-8 OFF
For additional information on wiring ports for local and network operation, refer to
CABLE CONNECTIONS on page 3K-6.
$ Loopback Testing
The loopback configuration feeds the output of the Enhanced Communication Board to
the input. This configuration is used for testing the board via the diagnostic test
program of AIC. Refer to section 3C of this manual and to User Manual D4041 33XX
Diagnostics for details.
$ Setting Jumpers
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TABLE 3K-C - CONFIGURATION JUMPER SETTINGS (Continued)
This board, shown in Figure 3K-16, contains header W1. Note that a jumper is only
inserted into W1 during factory testing. These tests utilize special factory equipment setups
that are not offered for users. Normal operation is obtained without any jumper (open). Do
not insert a jumper into W1.
FIELD WIRING
The connections required for RSP are described below. The connections for RDPC are
generally the same as those described in Section 3A SI Board.
Each RDPC must be wired to separate, working 24 Vdc supplies as shown in Figure 3K-15.
This is necessary to achieve redundancy for DC power failures. If only one supply is used, a
failure of that supply will cause the whole redundant system to fail.
It is essential that each piece of equipment (RSP and two RDPCs) be grounded separately as
shown in Figure 3K-17. Although the RSP provides two CGND terminals (one on each
block) only one requires grounding since both points are internally connected.
In order to detect a watchdog failure, the Redundancy Switching Panel monitors the A/M
TRAN outputs of each RDPC (see Figure 3K-18). These outputs are open collectors that
respond to a failure two milliseconds (2ms) faster than the watchdog relay contact output. If
both A and B units are functioning normally, the open collector output will be a "low." If the
on-line unit should watchdog, the open collector will switch to a "high," causing the RSP to
It is essential that the SI Board of each RDPC be configured to provide an open collector
out-put for the A/M TRAN signal. Referring to Section 3A SI Board, this configuration is ob-
tained by setting jumpers W4 and W5 as follows:
The auxiliary status output is a bi-state signal that indicates which unit is on line. It may
be wired to an external device such as a visual or audible alarm to indicate the on line unit
has failed.
The auxiliary status output is an open collector output and, therefore, requires an external
power source and load as shown in Figure 3K-19. When the A-OUT status output is set low,
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Unit A is on line; when it is set high, Unit B is on line. Conversely, when the B-OUT status
output is set low, Unit B is on line; when B-OUT is set high, Unit A is on line.
Power Section
The power section of the RSP contains one power switch and two fuses as shown at the left
of Figure 3K-13. The upper fuse protects power supply A and the lower one protects power
supply B. These fuses should be checked at the time of the initial startup and whenever a
unit fails. Note that these fuses, if blown, will not halt operation of either unit A or B but
they can disable the RSP and prevent communications.
$ Ready LEDs
A Ready LED is associated with each unit. When lit, these LEDs indicate that the unit is
functioning normally and is capable of serving as an on-line unit. Either unit A or B can
be assigned as the on-line unit depending upon user preference.
$ On-Line LEDs
When lit, either of these two LEDs will identify the on-line unit. The LED for the backup
unit will always be off.
$ Fail LEDs
These LEDs are normally off and only light to indicate that a unit has gone into a watch-
dog condition or its power has failed.
The Data Transfer (Data Copy) indicator lights when a packet of data is transferred
from the on-line unit to the backup unit.
$ Man-Sel-Dis LED
This LED is normally off and lights only when manual selections are disabled because of
previous failures.
$ Power LED
This LED lights when the RSP is powered. It remains lit as long as power supply A or B
is operating.
This two-position rocker switch gives the user the option to select unit B or A (Man or
Sel) as the on-line unit. The switch labels on the cover denote the position for either
selection. The user should note that it will not be possible to select the on-line unit if
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either unit has failed (both the Fail LED and the Man-Sel-Dis LEDs will light to indicate
a failure). Both units must be operating normally to affect a change.
This momentary switch enters Unit A or B as the on-line unit when starting the system
for the first time. The actual selection of the on-line unit is determined by the setting of
the Man-Sel (Unit B/A) switch described above. Pressing either end of the Reset switch
enters the selected unit as the on-line unit.
It is necessary to press the Reset switch to clear the Man-Sel-Dis LED after completing
repairs of a failed unit. Doing this will also configure the RSP for the mode indicated by
the Man-Sel (Unit B/A) switch as noted above. Make sure that this switch is in the
correct position before pressing the Manual Reset Switch.
When starting a system for the first time, the following equipment will be required:
2. Turn on both 24 Vdc power supplies. Also, turn on the RSP and both RDPCs.
3. On the RSP, connect the minus (-) lead of the DMM to the CGND terminal and the
(+) lead to the left side of the fuse block (F1) (Figure 3K-13). Note the DMM reading.
Move the (+) lead to the right side of F1. Both readings should be 24 Vdc (nominal). If
the second reading can't be obtained, check the fuse. Replace the fuse with the type
listed on the label. If the fuse continues to blow, find the problem source before
proceeding.
5. Check that the LEDs shown in Figure 3K-14 are displaying the following conditions:
7. Load the AIC program into the PC as instructed in the AIC manual (D4042). Also,
place the ACCOL load disk into the appropriate drive.
8. Connect the PC to any port of the RSP capable of accepting a cold download. The
need for a cold download occurs when the RDPC is started for the first time or when
the Reset Button (Located on the CPU Engine Board) has been pressed. Once the
reset cycle has completed, all RDPC outputs will be set to default values as the
RDPC awaits a download. Ports J1C through J4C shown in Figure 3K-11 can be
used for a cold download. If all these ports are assigned, remove the external
connection from port J1C and use it for this purpose.
Note
9. Referring to the AIC manual, bring up the On-Line Top Level Function Menu on the
PC screen and enter the poke point labeled, "Download Current ACCOL File." This
action will indicate a download.
10. After downloading Unit A, the On-Line LED for Unit A will light to verify the entry,
and the Data Transfer (Data Copy) LED will light or flicker to indicate that Unit A is
side-loading its data into Unit B. Finally, the Ready LED for the Backup Unit will
light to indicate it is on standby.
11. If it is desired to configure Unit B as the on-line unit, set the Man-Sel (Unit B/A)
switch to Man (Unit B) and press the Manual Reset button. The On-Line LED for
Unit B will light while Unit A's will go out. Similarly, the Ready LED for Unit B will
go out while Unit A's will light up. Unit B is now the on-line unit.
12. Remove any DMM connections and reconnect the port used for testing (where ap-
plicable). Check the on-line functions of the system using the AIC (ACCOL II In-
teractive Compiler).
The model number is stamped on a data plate affixed to the redundancy equipment. System
features can be identified by comparing the data plate model number to Table 3K-D.
A 3332 system can also include attachments. The attachment numbers, which only appear
in the sales order, identify the type and characteristics of the I/O modules furnished with
the DPC. The attachment number codes are identified in Table 3K-E.
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Table 3K-D - MODEL NUMBER BREAKDOWN
A = PACKAGING
B = INTERNAL POWER
1 = +24 Vdc
0 = None Included
D = CERTIFICATION
0 = None
1 = FM Approved **
E = CABLES
1 = Long
2 = Short
Note: These tables are only provided for customer product identity and not
for sales ordering purposes.
Attachment numbers for redundancy will have an "A" prefix followed by five digits (E
nnnnn). Identify the attachment code number assigned to each numerical position and
reference to the list below. The features will be listed in the corresponding row. (Note: This
table is only for product identity and not for sales ordering purposes.)
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TABLE 3K-E - ATTACHMENTS FOR REDUNDANCY (2of 2)