TM

Classic I/O Redundancy

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Objectives
Upon completion of this module you will be able to: Define Classic I/O Redundancy functionality Define Classic I/O Redundancy components Define Classic I/O Redundancy wiring connections Configure Classic I/O Redundancy modules Define Classic I/O Redundancy user interface

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Classic I/O Redundancy

Controller Primary Backup

Classic I/O Switchover Panel

Field Instrument
(-) (+)

Field Wiring

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Classic I/O Redundancy

Classic I/O Redundancy provides 1:1 redundancy for classic I/O cards as shown above. The following I/O cards are supported: AI, 8-channel, 4-20mA (without HART)(2-wire only) AO, 8-channel, 4-20mA (without HART) DI, 8-channel, 24 VDC, Isolated DI, 8-channel, 24 VDC, Dry Contact DO, 8-channel, 24 VDC, Isolated DO, 8-channel, 24 VDC, High-side Automatic switchover will occur in the event of a primary I/O card failure. The operator is given notification of a switchover at the operator display. Note: Outputs to process equipment will be interrupted during switchover. (Two millisecond is typical if the card is configured to Hold Last Value) In addition, outputs to process equipment may be at an indeterminate state during switchover. Inputs to the controller remain at last value during switchover.
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Classic I/O Redundancy

Redundancy Control Module Controller Primary DO 24VDC High Side Switch Card Backup

(+)

(-)

Pri.

Bkup

16-pin mass termination blocks

Field Instrument
(-) (+)

Field Wiring
(-) 2 4 6 8 10 12 14 16

(+) 1 3 5 7 9 11 13 15

Mass Term. Field Wiring Option

Redundancy Switchover Panel

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Classic I/O Redundancy

The primary and backup I/O cards shown above are connected to the redundancy panel using mass termination blocks and two cables. The switchover panel has eight relays that switch the eight channels from one card to another. A discrete output signal is wired to the switchover panel to trigger the switchover. A redundancy control module in the controller monitors the integrity of the primary and backup card to determine when a switchover should be triggered. Switchovers are caused by the following events: Hardware failure within the active card. Bad integrity on an individual channel. Communications failure between the active card and the controller. Removal of the active card from the carrier. Manual Switch. The redundancy control module is created from one of four module templates to simplify configuration. The type of module template that should be used is based on the type of I/O cards. For example, if the primary and backup cards are discrete outputs, the OUTPUT_DISCRETE template should be used.
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Redundancy Example
Redundancy Control Module Controller Primary DO 24VDC High Side Switch Card Backup

(+)

(-)

Pri.

Bkup

16-pin mass termination blocks

Field Instrument
(-) (+)

Field Wiring
(-) 2 4 6 8 10 12 14 16

(+) 1 3 5 7 9 11 13 15

Mass Term. Field Wiring Option

Redundancy Switchover Panel

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Workshop Setting Up Classic I/O Redundancy

The following workshop steps you through the hardware and configuration setup necessary to implement redundant I/O. The example shown above provides a redundant discrete output to a critical discrete device. The following tasks are required. Task 1. Task 2. Task 3. Task 4. Task 5. Install the I/O Hardware. Configure the I/O cards. Configure the redundancy control module. Download the controller. Verify operation.

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Workshop - I/O Hardware Installation

DO 24VDC High Side Switch Card Slot 2 Primary DO 24VDC High Side Slot 1

Backup DO 24VDC High Side Slot 3

(+)

(-)

Pri.

Bkup

16-pin mass termination blocks

Field Instrument
(-) (+)

Field Wiring
(-) 2 4 6 8 10 12 14 16

(+) 1 3 5 7 9 11 13 15

Mass Term. Field Wiring Option

Redundancy Switchover Panel

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Workshop - I/O Hardware Installation

Step 1. Step 2. Step 3. Step 4. Install the primary discrete output card in slot 1 with a 16 pin mass termination block. Install the backup discrete output card in slot 3 with a 16 pin mass termination block. Connect the primary and backup cards to the redundancy switchover panel using a 16 pin mass termination block cable as shown above. Install the switch card in slot 2 with an I/O termination block.

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Workshop - I/O Hardware Installation

Step 5. Wire slot 2, terminal block connection 1 to the + connector on the redundancy switch panel. Wire slot 2, terminal block connection 2 to the connector on the redundancy switch panel. This example uses channel 1 on card 2 as the switch signal. Wire the field instrument + connection to terminal block connection 1. Wire the field instrument connection to terminal block connection 2. This example uses channel 1 to control the Field Instrument.

Step 6.

Note: The mass termination block in the lower right hand corner of the redundancy switchover panel would be used if the field instrument were wired to the control system through mass terminations.

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Workshop - I/O Card Configuration

DO 24VDC High Side Switch Card Slot 2 Primary DO 24VDC High Side Slot 1

Backup DO 24VDC High Side Slot 3

(+)

(-)

Pri.

Bkup

Field Instrument
(-) (+)

Field Wiring
(-) 2 4 6 8 10 12 14 16

(+) 1 3 5 7 9 11 13 15

Redundancy Switchover Panel

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Workshop - I/O Card Configuration

Configuring I/O cards for redundancy does not require any special card configuration. Define the primary, secondary and switch cards as standard I/O cards. The redundancy functionality will be provided with the redundancy control module. The figure below shows the cards configured as a classic DO Card, 8 Ch, 24VDC, High Side.

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Workshop - I/O Channel Configuration

Channel 1 XV1_SWITCH

Channel 1 XV1_PRI Pri.

Channel 1 XV1_BACKUP Bkup

(+)

(-)

Field Instrument
(-) (+)

Field Wiring
(-) 2 4 6 8 10 12 14 16

(+) 1 3 5 7 9 11 13 15

Redundancy Switchover Panel

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Workshop - I/O Channel Configuration

The most important part of channel configuration is that they are enabled as shown below. XV1 is the name of the device in the example below. Naming conventions used for the DSTs are shown below: XV1_PRI for the primary channel (recommend Fail_Action_Mode=Hold last value) XV1_SWITCH for the switch channel XV1_BACKUP for the backup channel

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Workshop - Redundancy Control Module

Redundancy Control Module Controller CTLR1 Channel 1 XV1_SWITCH

Channel 1 XV1_PRI

(+)

(-)

Pri.

Bkup

Channel 1 XV1_BACKUP

Field Instrument
(-) (+)

Field Wiring
(-) 2 4 6 8 10 12 14 16

(+) 1 3 5 7 9 11 13 15

Redundancy Switchover Panel

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Workshop - Redundancy Control Module

The redundancy control module monitors the overall integrity of the primary and backup cards. In the event of an integrity error on the primary card the control module energizes the switch channel and switches the relays to the backup card. The redundancy control module should be created from one of the module templates based on the primary and backup card types. The example below uses the OUTPUT_DISCRETE since the primary and backup cards are discrete outputs. Drag n drop PUTPUT_DISCRETE to a plan area and rename the module RED_OUT_DIS

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Workshop Redundancy Module Configuration

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Workshop Redundancy Module Configuration

The parameters to be modified are shown above. Step 1. Modify the PRI_OINTEG and BCK_OINTEG diagnostic parameters that evaluate the overall integrity of the primary and backup cards. PRI_OINTEG = CTLR1/IO1/C01/OINTEG (Card 1) BCK_OINTEG = CTLR1/IO1/C03/OINTEG (Card 3) Modify the PRI_DESC and BCK_DESC description fields that appear on the faceplate. PRI_DESC = CTLR1 Slot 1 BCK_DESC = CTLR1 Slot 3 Modify DO, an External Reference that identifies the switch channel. DO = CTLR1/IO1/C02/CH01/OUT_D (Card 2) Step 4. Modify PRI_CH1 and BCK_CH1, External References that identify the primary and backup channels. PRI_CH1 = CTLR/IO1/C01/CH01/OUT_D BCK_CH1 = CTLR1/IO1/C03/CH01/OUT_D
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Step 2.

Step 3.

Workshop Redundancy Module Configuration

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Workshop Redundancy Module Configuration

In the following, all references to channels 2-8 will be deleted. All channel 2 references are selected for deletion in the figure above. Complete the module configuration as follows: Step 1. Step 2. Assign the module to CTLR1. Define module properties. Primary Control Display = users choice Detail Display = REDDO_DT Faceplate Display = REDIO_fp Execution Scan Rate = 1 sec Note: FRSI recommends that you set the scan rate equal to the fastest module that will utilize this redundancy module (to reduce unnecessary controller loading) Step 3. Step 4. Save the module, name it RED_OUT_DIS. Download the controller.
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Workshop - Verify Functionality

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Workshop - Verify Functionality

The figure above illustrates the pre-configured faceplate used for the redundancy control module. Note the following: The arrow indicates which card is connected to the field instrument through the redundancy switchover panel. When the switch signal is de-energized the primary card is connected to the field instrument. This is the normal mode of operation. Redundancy Status = Enabled which means an automatic switchover will occur in the event of a primary card failure. The user may force a switchover by pressing Use Primary Card, Use Backup Card. Normally the Automatic button should be selected which will Enable a switchover in the event of a failure.

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Workshop - Switchover Indication

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Workshop - Switchover Indication

The figure above illustrates a switchover indication. Note the following: The arrow indicates the backup card is connected to the field instrument through the redundancy switchover panel which means the switch signal is energized. Redundancy Status indicates a switchover has occurred. Also notice a primary integrity alarm is active on the bottom of the faceplate.

The following sequence should be performed to get the system back to a normal redundancy mode with auto switch enabled. Step 1. Step 2. Replace the bad primary card. Press the Reset button on the faceplate. This will switch back to the primary card as well as Enable Redundancy status for automatic switchover.
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Workshop - Control Module Configuration

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Workshop - Control Module Configuration

This example has covered the installation and configuration of the redundant I/O scheme. The last topic to mention is the control modules that will utilize the redundancy scheme. XV1 is the device tag of the critical instrument. Control module XV-101 has been configured to to OPEN and CLOSE this valve. This module was configured the same as other modules with one exception. The output of the DC1 block is not be tied directly to a DST. The output is exposed F_OUT_D1 and wired to the DO1 parameter on the module block referencing the redundancy module. By configuring the module in this manner the output is always sent through the redundancy control module to determine which card should send the signal to the field based on overall card integrity.

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Summary
You should now be able to: Define Classic I/O Redundancy functionality Define Classic I/O Redundancy components Define Classic I/O Redundancy wiring connections Configure Classic I/O redundancy modules Define Classic I/O redundancy user interface

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