How to connect 800 PLCsnd Work Station in Redundancy?
In my new project(first of this type) I have redudent PM864 CPU.
2Nos of Engineering (1 for redudency) workplace and 2Nos of operator workplace(1 for redudency).
Now I don't know how to connect my both CPU and all 4 PC system (2 Engineering and 2 operator) so I can get network redudency?
Thanks in adavance.
Voted best answer
Redundant PM864 controller will connect to Operation server through OPC server.Operation server will be having the network redundancy protocol called RNRP(Redundant network routing protocol). This protocol will take care of network redundancy. Redundant CPU and all 4 PC's are connected with ethernet switch. Engineering station-Control builder is having inbuilt interface to communicate to PM864 and operation server will communicate to controller via AC800M OPC server
Important point is 800xa is having Aspect server for managing the graphics part and connectivity server for handling the real time data. In your configuration you have mentioned as operator workplace(My understanding is this should be combined aspect and connectivity server)
Kindly go through your licensefile and understand what kind of configuration you have?
Refer more details from RNRP configuration section in 800xa manual.
Kindly post if you have further questions
As mentioned, in addition to not only the physical redundancy of the system (i.e. redundant computers each with a minimum of two network cards and redundant AC800M controllers, in your case PM864 units), you do need to make sure that the licensing that you have been provided also includes redundancy support. Now the 800xA system includes the licensing support for redundant ASPECT servers, so you need to be sure that you have licensing for redundant AC800M Connect Server support, which is provided through the "Tag Count" licensing. For example, if your system is very small and only has 100 Tags and you want redundant Connectivity Server communication, your licensing should include PART NO#: 3BSE061236R1; B050 - 100 tags, redundant, 800xA 5.1; (Enables tag access through redundant Connectivity Servers), this part number and/or the quantity of these purchased will vary based on your tag count but you will need the redundant tags.
Also, as far as redundancy goes, you will also need to determine if you want to run the controllers on the same communication network as the operator consoles or if these are to be physically separate. If you want them separate, then of the four computers, the two running the AC800M Connectivity Server function will have four physical network ports, two to connect to the controllers on the Control Network and two to connect to the other consoles over the Operations Network, the other two PCs that are not the Connectivity Servers only require two network ports to connect to the operations network. This decision to split the networks is made in part on your company's philosophy as far as separating control communication with the console to console communication as well as communication loading on the control and operations network. But also, if you plan to connect your console operations network to other things, like your company network, you may also want to consider using separate control and operations networks. 800xA supports both architectures, so you need to decide which is best for your application needs. As a matter of course, when workign with our customers we almost exclusively split the two networks. The cost to do so adding two additional network ports to two computers is virtually nothing where the added security more than justifies the addition.
Attached is an example bill of materials and a system architecture drawing of one possible redundant implementation based on running the Aspect Server, Connect Server and Operator Workplace on one pair of computers and the Engineering Workplace on separate computers. The architecture drawing is based on your statement that you would run the Engineering Workstation functionality on separate PCs from the Operator Workstation Functionity. The system sizing is:
100 Digital Inputs
100 Digital Outputs
100 Analog Inputs
100 Analog Outputs
300 Redundant Tags
2 x Engineering Workstation Support
2 x Operator Workstation Support
Redundant Power Supplies for Control & I/O
Now, one additional thing to keep in mind as far as licensing is concerned is that when the engineers at ABB designed the system it appears that they assumed that the engineering would always be done from a PC that would also server as an operator workplace. I say this because over the years we have found that when running the engineering workstations on computers separate from the operator workplace computers that some of the functionality utilize graphics elements and other components of the operator workplace functionality, although they are not actually operator workplace stations. In this case, if you only have 2 x Operator Workplace licenses for the system and you already have two operator workplace licenses open and running on two different computers, if on the Engineering Workplace Computer you open/utilize somthign that uses some of the Operator Workplace functionality, the system will think that you are trying to open a third or possibly fourth Operator Workplace, depending on whether one or two people are workign on the dedicated Engineering Workplace computers, in which case you will get a license violation error relating to the number of operator clients open. The only way that we have ever been able to get around this licensing warning from appearing is to either:
1. Always run the Engineering Workplace functionality on the same PC that we are runnign the Operator Worplace functionality.
2. Purchase at least one additional Operator Workplace license, which in effect will "float" in the system and only be allocated when you access the "operator client elements" from the engineering workstation.
If you only have one person engineering at a time, one additional license is sufficient but if you have two operator workstations open and you are performing engineering from two separate Engineering Workstation PCs then you would possibly need four Operator Worplace Licenses to avoid a temporary license warning.
The license warning that appears when you have the engineering workplace open along with the two licensed Operator Workplace licenses all on separate PCs will not impact the operation of the system in any way and is really just a nuisance for the engineer as it will appear about every 10 - 15 minutes when he has the EWS station open and he is accessing OWS elements from within the tools.
Perhaps there is a way around this from happening and if so, none of the ABB people that we work with have been able to tell us or show us how to prevent this from happenign when performing engineering from a separate PC than the ones being used as the operator workplace stations.
I’ll strongly recommend using the manual listed in one of the answers.
From a network point of view, it seems your system is small, then I would say you only need one redundant network, this means, you need at least two switches and each ABB node (workstation, PM864) should be connected to both , each PM864 already have two ports and for your PC’s you need to specified them with two NIC cards.
RNRP is the mechanism in charge of the redundancy, when standard IP addresses are configured in all network nodes most of the RNRP configuration is done automatically thru the 800xA system automatic installation.