Opto 22 introduces SNAP PAC redundancy option kit

Hardware and software let users build redundant PAC systems easily.

04/01/2010


Opto22_SnapPAC-with-Redunda.jpgOpto 22, developer the SNAP PAC family of programmable automation controllers, I/O, and accessories, has released the SNAP PAC Redundancy Option Kit (SNAP-PAC-ROK), which enables users to design an Ethernet-based redundant control system with maximum reliability and distributed intelligence.

Using standard Opto 22 S-series SNAP PACs, SNAP Ethernet I/O, and the newly announced PAC Project Professional 9.0 software suite, users can configure automation systems with dual programmable automation controllers (PACs) that essentially synchronize and run in parallel. In the event one controller fails or is knocked offline, the other controller will assume command and continue to execute the control program and the processes it runs, with no interruption or restart necessary.

This feature, known as "redundancy," provides many advantages. Foremost among these is a significant reduction in the control system's mean time between failures (MTBF), and thus even greater levels of reliability for process-oriented applications in the manufacturing of semiconductors, thin film LCD, and other high-value product batches. Redundant control systems also prove advantageous (and are frequently mandated) for processing, handling, and transport of chemicals, pharmaceuticals, and oil and gas products and byproducts.

IC Engineering Project Manager Ryan McCollum has implemented large-scale automation projects at the research and testing facilities of one of the world's largest oil companies. He says, "Redundancy, combined with the larger memory and better multi-tasking capabilities of the Opto 22 PACs, make them superior to most PLCs. The Opto 22 hardware also provides a variety of other useful, often exclusive capabilities."

Redundant Opto 22 control systems created with the SNAP PAC Redundancy Option Kit provide several unique features, according to the company. For instance, the two identically configured controllers (active and backup) are able to swap roles in the redundancy scheme at any time, allowing flexibility during system start-up and commissioning.

The kit includes the SNAP PAC Redundancy Arbiter, which is a standalone processor that connects serially to both controllers. It and monitors and regulates their status, and maintains synchronization of the control program during system startup. The kit also includes the SNAP redundant power switch, which allows power re-starts to controllers in the event of failure and during firmware upgrades.

Opto22_PacProject9_PacContr.jpg
With redundant Opto 22 controllers , customers also can keep their control system online and operating even as they make changes to, or completely replace their control program. Once the new program is downloaded to one controller, it becomes active and the second controller is updated with the new instruction set. Customers can repeat this process as often as they like, as they test, fine tune, and configure their control program to their exact specifications. Similarly, customers seeking to make their existing system redundant need only to add the SNAP PAC Redundancy Option Kit, the latest version of PAC Project Professional, and a second S-series controller, which, upon commissioning, is automatically populated with the most current firmware and control program.

 

Other ways in which an Opto 22 redundant system differs from those of other automation suppliers: It uses the company's standard controllers, and it communicates over Ethernet using standard Cat 5 cabling. (No proprietary communication protocols, interfaces, or custom cables are required.)
See also: Opto 22 introduces PAC Project 9 control programming software suite

- Edited by Renee Robbins, senior editor
Control Engineering News Desk

PLCs, PACs, Programmable Automation Controllers news from Control Engineering



No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2013 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
The true cost of lubrication: Three keys to consider when evaluating oils; Plant Engineering Lubrication Guide; 11 ways to protect bearing assets; Is lubrication part of your KPIs?
Contract maintenance: 5 ways to keep things humming while keeping an eye on costs; Pneumatic systems; Energy monitoring; The sixth 'S' is safety
Transport your data: Supply chain information critical to operational excellence; High-voltage faults; Portable cooling; Safety automation isn't automatic
Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Plant Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.

Maintaining low data center PUE; Using eco mode in UPS systems; Commissioning electrical and power systems; Exploring dc power distribution alternatives
Synchronizing industrial Ethernet networks; Selecting protocol conversion gateways; Integrating HMIs with PLCs and PACs
Why manufacturers need to see energy in a different light: Current approaches to energy management yield quick savings, but leave plant managers searching for ways of improving on those early gains.

Annual Salary Survey

Participate in the 2013 Salary Survey

In a year when manufacturing continued to lead the economic rebound, it makes sense that plant manager bonuses rebounded. Plant Engineering’s annual Salary Survey shows both wages and bonuses rose in 2012 after a retreat the year before.

Average salary across all job titles for plant floor management rose 3.5% to $95,446, and bonus compensation jumped to $15,162, a 4.2% increase from the 2010 level and double the 2011 total, which showed a sharp drop in bonus.

2012 Salary Survey Analysis

2012 Salary Survey Results

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.