M580 Redundant Configuration
Chapter 2: Overview of M580 Redundant ePAC
V2.0
Overview of M580 Redundant ePAC
Chapter Overview
● Module Presentation
● The Ethernet Backplanes
● CPU Specification
● X80 Redundant Power Supplies
● Operating States and Modes
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Next Generation for
Redundancy Solution
● Technologies have changed over the years
● Need to evolve and move towards a new generation
● Need to prepare for the future
➢ Quantum and Premium are platforms reaching Maturity
➢ Performances limitations not compatible with future architectures
▪ slow scan time, limited communication and data capabilities
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Main Key Features
● Controller with high system availability and network redundancy
● Use of existing Modicon X80 I/O modules, based on M340
● Support new range of Modicon eX80 I/O modules
● Embedded Ethernet Remote I/O (RIO) backbone, similar to that
launched with Quantum Ethernet I/O (QEIO)
● Ethernet backplane for better openness and flexibility: a fully
Ethernet PAC (ePAC)
● Mix Remote I/O, Distributed I/O and other devices on the same
Ethernet backbone
● Support on the Dual PWS Ethernet backplane with redundant
power supply modules
● Offers easy migration from supported legacy hardware platforms
● Offers easy integration to existing Quantum Ethernet Remote I/O
(QEIO)
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Physical Characteristics
● Size same as the Modicon M580 ePAC
● Take advantage of the existing modules of Modicon M340 PLC:
●Digital I/O modules
●Analog I/O modules
●Communication modules, etc…
● CPU module occupies 2 slots of the backplane
● Slightly longer in size
● 2 connectors on the back of CPU module
● X-Bus connectivity (1)
●to support existing M340 / X80 modules
● Ethernet connectivity (2)
●to support new Ethernet / eX80 modules
● Rotary selector switch to set CPU as A or B Note: If the A/B/Clear rotary switch is on CLEAR, at
power on, the application will be erased from both
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internal flash memory and the SD card. 5
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Physical Overview
● Three M580 redundant ePAC CPU models:
● BME H58 2040
● BME H58 4040
● BME H58 6040
● CPU coated version - BME H58 *040C
Description
1 LED Display
2 MAC Address
3 Mini-B USB Connector
4 RJ45 Ethernet Port - Service port
5 RJ45 Ethernet Ports - Device Network ports
6 1 Gbps Ethernet sync-lnk interface socket for RJ45 or Fiber Optic
7 Product QR code
8 X-Bus and Ethernet connections to backplane
9 Slot of optional SD memory card
10 Locating and earthing connection to backplane
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LEDs Display
● Each LED on the CPU front panel has a dedicated function:
● Diagnostics,
● Troubleshooting
● etc…
LED Description
RUN CPU running state
ERR CPU or system detected internal fault
I/O External fault from I/O modules
DL Firmware is currently being downloaded
REMOTE RUN Remote CPU is running
BACKUP Indicate inconsistent stored application
ETH MS MOD STATUS: Ethernet port configuration status
ETH NS NET STATUS: Ethernet connection status
A Local CPU is set to A
B Local CPU is set to B
PRIM Local CPU runs as primary
STBY Local CPU runs as standby (flashes: cannot see the other CPU)
FORCED I/O At least one I/O points of digital module is forced
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Embedded Ethernet Ports
● Each M580 redundant CPU is equipped with 4 embedded
Ethernet ports:
● 1 x Service port (1)
●For diagnosis , Unity Pro, HMI, etc…
● 2 x Device Network ports (2)
●RIO and DIO scanner service with RSTP
● 1 x CPU sync-link (3)
●Dedicated port using SFP socket For (1) & (2)
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CPU Sync-link
● Data exchange is via the dedicated Ethernet connection on the
M580 redundant CPU
● The connection has a 1 Gigabit Ethernet range
● 1000BASE-T Twisted-pair cabling (Cat-6, Cat-7) 100 meters
● A selectable SFP socket is required:
● 490 NAC 0100 - RJ45 (max. length = 100m)
● 490 NAC 0201 - Fiber Optic LC Single Mode (max. length = 15km)
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SD Memory Card – BMX RMS 004GPF
● The SD memory card BMX RMS 004GPF is optional and is used for:
● Application backup (size = 200MB for redundant CPU)
● Note:
- Data written in SD Card is not managed by the redundancy system.
Reason is due to impossibility to have consistency between the
peers. User has to manage manually.
● The memory card is of "Industrial Grade" and formatted for use
with Schneider Electric Modicon M580 CPU only.
● Only the BMX RMS 004GPF SD memory card is
supported by the Modicon M580. SD cards from
the Modicon M340 are NOT supported by the
Modicon M580.
● Generate a rising edge on bit %S65 before remove
SD memory card.
A GREEN LED (without marking) located
under memory card door of the CPU,
indicates that access to card is ongoing.
Modicon M580 Redundant Configuration V2.0 It must be OFF to remove the SD-Card.
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Exercise
Identify the part of the Redunant CPU (p2-8)
Learning Outcomes
● By the completion of this exercise you will:
➢Be able to remove and install the SFP modules
➢Understand the different parts and functions
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The Ethernet Backplanes
● The M580 redundant ePAC uses the same range of backplanes
as the M580 controllers.
● The backplanes have Ethernet onboard, and to support existing
modules they also have X-Bus connectivity:
● Having both connectors onboard allows for the existing range
of M340 / X80 modules to be incorporated into an M580
architecture.
❖ Does not support extension of Modicon Premium racks.
❖Each ERIO drop can support one extension of M340 rack.
❖No extension rack on main local racks of redundancy system.
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The Ethernet Backplanes (cont.)
Redundant Power Supply Backplanes
● Dual Power Supply Ethernet Backplanes are developed to comply
with the redundant power supply modules:
● BMX CPS 4002 (H) – 100 - 240Vac, 40W for 24V; 15W for 3.3V
● BMX CPS 4022 (H) – 24 - 48Vdc, 40W for 24V; 15W for 3.3V
● BMX CPS 3522 (H) – 125Vdc, 40W for 24V; 15W for 3.3V
● Compatible with single power supply racks (BMX & BME) but only
works as a standalone power source
● Existing BMX CPS cannot be used on the dual power supply racks.
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The Ethernet Backplanes (cont.)
● The following table shows all the references including non-
Harsh and Harsh version (with suffix "H"):
Ethernet & X-Bus only
Reference Description
X-Bus Slot Slot
BME XBP 0400
4 Slots Ethernet Backplane 4 0
BME XP 0400H
BME XBP 0800
8 Slots Ethernet Backplane 8 0
BME XBP 0800H
BME XBP 1200
12 Slots Ethernet Backplane 8 4
BME XBP 1200H
BME XBP 0602
6 Slots Ethernet Backplane with Dual Power Supply 6 0
BME XBP 0602H
BME XBP 1002
10 Slot Ethernet Backplane with Dual Power Supply 8 2
BME XBP 1002H
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The Ethernet Backplanes (cont.)
Ethernet Backplanes Technology
● Ethernet is the main communication medium in the backplane
● Embedded Ethernet Switch inside the backplane
● Speed of 100Mbps with full-duplex
❖ Not all slots have Ethernet connectivity
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CPU Models
● 3 references of M580 redundant ePAC CPU models:
● BME H58 2040 - Level 2 CPU
● BME H58 4040 - Level 4 CPU
● BME H58 6040 - Level 6 CPU
● CPUs with coated version - BME H58 *040C
H58 2040 H58 4040 H58 6040
Max. number of Drops 8 16 31
Program code (MB) 8 16 64
Max. HSBY transfer Data (MB) 0.7 2 4
Performance BOOL Kinstr/ms 10 40 50
Max. number of eNOC 2 3* 3* * Due to power consumption
Support of QEIO No Yes Yes
Support of 984LL Programming No Yes Yes
HSBY Link 1 Gigabits selectable type by SFP socket
SFP sockets:
➢ 490 NAC 0100 - RJ45
➢ 490 NAC 0201 - Fiber Optic LC Single Mode
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Comparison
● M580 Redundancy system
very much faster than
Quantum HSBY system
● M580 STBY CPU is updated
with user
● Selectable programs
(Sections)
● Selectable data variables
(max. 4MB)
● MAST task of M580 CPU
must be in PERIODIC mode
● FAST task is optional.
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CPU Specifications
● Table shows the functional characteristics the Redundant CPUs:
BME H58 2040
BME H58 4040
BME H58 6040
Max number of Local Racks 1 1 1
Max number of Remote I/O drops of 2 racks 8x2 16 x 2 31 x 2
Max network modules (+1 embedded Ethernet in CPU) 2+1 3* + 1 3* + 1 * Due to power
1 x Service consumption
Comm. Ports 2 x Device
1 x HSBY
Integrated
CI Devices + CI Modules 64 64 128
Memory In + Out (KB) 16 + 16 24 + 24 32 + 32
Including for FAST 3+3 5+5 6+6
DI Devices + DI Modules 64 64 64
Memory In + Out (KB) 2+2 2+2 2+2
Program (Mbytes) 8 16
❖64 Mbytes
Max Data (Kbytes) 768 2048
Memory
Max retained Data (Kbyte) 768 2048 4096
Max HSBY transfer Data (Kbyte) 768 2048 4096
Data storage (GB) 4 4 4
Application Specific Channels 32 64 256
Boolean application execution (Kinstr/ms) 10 40 50
❖ The BME H58 6040 CPU supports the sum of
program and data up to the stated maximum.
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Exercise
CPU Distinction (p2-16)
Learning Outcomes
● By the completion of this exercise you will:
➢Configure the identify of the physical redundant processor
CPU A CPU B
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X80 Redundant Power Supplies
● The characteristics of redundant power supply are:
● Delivers 40 W with 24 Vdc & 3.3 Vdc backplanes
● Compatible with BMX and BME racks, works as standalone PWS
● Required dual PWS Ethernet backplane rack for install 2 PWS
● Can install in main rack & remote drop rack with Ethernet backplane
● Can install 2 PWS and mixed AC and DC modules on same rack
● BMX CPS 4002 / 4022 / 3522
❖ standard version for temperature 0°C to 60°C
● BMX CPS 4002H / 4022H / 3522H
❖ hardened version for temperature -25°C to +70°C
without any de-rating Display Panel
AC Power
Terminal Block RESET Button
NC
NC Alarm Relay
PE Terminal Block
AC Neutral
1
AC Line
2
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X80 Redundant Power Supplies (cont.)
●Display Panel
●ACTIVE: ON – Module is on MASTER mode
OFF – Module is on SLAVE mode
●OK: ON – All output voltage working correctly
Reset button not active
OFF – 24VDC & 3.3VDC not O.K.; Reset button active
●RD : ON – 24VDC & 3.3VDC are O.K.; Reset button not active
(redundancy)
OFF – One of power supply module stopped operating
Reset button active
Note:
During module auto-testing mode, ACT and RD LEDs will blink.
At the initial power-up, the MASTER is located at the left most of the backplane.
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X80 Redundant Power Supplies (cont.)
●Alarm Relay Terminal Block 1
2
1
●Contact type: Normally open
●Rated: 24 VDC 2A; 240 VAC 2A
●Reset Button
●forces a reset of the CPU module
●Init all modules with a COLD START
●forces ALARM relay contact to open state
●forces the "OK" LED to be switched off
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X80 Redundant Power Supplies (cont.)
Compare Quantum & X80 Redundant Power Supplies
● Current Quantum Solution: ● The X80 Redundant Power Supply
- 2 PWS sharing same load - A True Redundant PWS (Master / Slave)
- same MTBF Only one active at a time
100 100
PS1
Load (%)
Load (%)
PS2 PS1
PS2
0 0
Time Time
- Same aging, leading to - Allow more Time To Replace ( MTTR)
components stop - Advanced diagnostics available
operating when full load (% wearing, uptime duration)
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X80 Redundant Power Supplies (cont.)
●Management of MASTER and SLAVE Power Supply mode
●Always checks 24Vdc and 3.3Vdc levels. If stops will switchover
Diagnostics accessible with EFB:
(PWS_CMD & PWS_DIAG)
• Ambient temperature, Voltage and
Current on 3.3Vdc and 24Vdc
• Operating time as master / slave since last
power-on
• Operating time as master / slave since
manufacturing
• Remaining time before preventive
maintenance
• And many more …
●At initial power-up, module on the left most backplane will be MASTER
●When master stops operating, the SLAVE take over. It will take role and
stay as MASTER, even the abnormal module is replaced
❖ Redundant power supplies function is available
on M580 CPUs with OS firmware V2.10 or later.
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X 80 Redundant Power Supplies (cont.)
●To perform a Slave test, there are 2 possible options:
●Auto Test - performed on the SLAVE, every 10 hours, transparently
from process point of view. If the slave is declared stop working, the
redundancy operation will be activated.
●During the SLAVE testing, the ACTIVE & RD LEDs flash
continuously
●Programming using EFB, Elementary Function Blocks
●PWS_DIAG - provide user diagnostics information on the
status of the two power supply modules
● PWS_CMD - swap to test the role of power supply between
MASTER and SLAVE mode
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Exercise – Optional
Install Power Supply Library (p2-22)
Learning Outcomes
● By the completion of this exercise you will:
➢Install the “Predictive Maintenance” library into Unity Pro
Programming software
❖ Note: Power Supply Library (Predictive
Maintenance Library) is available in Unity Pro V13.1.
Modicon M580 Redundant Configuration V2.0 This Exercise is not necessary.
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Operating States
● There are basically 4 operating states of M580 redundant ePAC:
● Run PRIMARY - Main
●Executes application programs (Sections) continuously
●Updates all remote I/Os
●Update STBY CPU (if ALIVE) with all I/Os, user choice of Programs & Data
●Note: Both PACs can be PRIM if NO connection between the two
PACs; (NO HSBY sync-link, NO EIO links and NO link on Service port).
● RUN STANDBY - Backup
●Check whether PRIM exist during each scan cycle
●Check any command from PRIM CPU
●Tell PRIM that I’m ready to take over
●Checks for any mismatch in firmware and programs
●Continuously check connection status of its Remote I/O drop link
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Operating States (cont.)
● The M580 redundant ePAC operating states continues:
● WAIT
●Depending on the HSBY setting behaviour, the CPU will executes:
– All application programs (Section) of the MAST task, OR
– Only the selected application programs, OR
– None of the application program in MAST task, AND
– No I/Os data are written
●This state can be manually activated or can be detected by the CPU
●Cannot find PRIM CPU, itself will try to change state to RUN PRIMARY
●If PRIMARY CPU is ALIVE, it will check whether can switch to RUN
STANDBY state
● STOP – Not Running
●NO application program running
●NO controls of process
●Will NOT be part of the Hot Standby system
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Table of Operating States
● Below summaries the possible operating states of the 2
controllers for the M580 redundant ePAC:
❖ Both Controller A and Controller B can be in RUN
PRIMARY state when they are completely disconnected
from each other.
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Running Conditions
● Table below provides criteria for the CPU to be in running
PRIMARY or running STANDBY mode:
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Operating State Scenarios
● Each scenarios will focus on the condition of the:
● HSBY link between CPU A and CPU B
● ERIO link between CPU A and CPU B
● ERIO connections between each CPU and one or more ERIO device
adapters over the RIO main ring
● The M580 Redundant CPU module with its A/B rotary switch set to:
● "A" will be defined as "CPU A"
● "B" will be defined as "CPU B"
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Operating State Scenarios (cont.)
Scenario 1
● Hot Standby system connections are functioning and operational.
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Operating State Scenarios (cont.)
Scenario 2
● Hot Standby link is not operational.
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Operating State Scenarios (cont.)
Scenario 3
● A single break exists in ERIO main ring.
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Operating State Scenarios (cont.)
Scenario 4
● Loss of ERIO link between CPUs and CPU A loss its RIO adapter.
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Operating State Scenarios (cont.)
Scenario 5
● Loss of ERIO link between CPUs and each CPU link to its RIO
adapter.
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Exercise
M580 Redundant System States (p2-32)
Learning Outcomes
● By the completion of this exercise you will:
➢Understand the different operating states
➢Able to identify different operating state scenarios
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Chapter 2 - Summary Questions
● The following questions will help to check understanding of the
topics covered in this chapter:
● What are the main key features of the M580 Redundant ePAC offer?
● What are the new M580 Redundant CPU models in the initial offer?
● What is the purpose of the dedicated Ethernet port on the M580
Redundant CPU? Which type of SFP sockets are used on this port?
● What is the purpose of having a rotary switch behind the Redundant
CPU?
● Which of the Ethernet backplane support dual power supply?
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Overview of M580 Redundant ePAC
Chapter Summary
● Module Presentation
● The Ethernet Backplanes
● CPU Specification
● X80 Redundant Power Supplies
● Operating States and Modes
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