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Proficy* HMI/SCADA - iFIXENHANCED FAILOVERVersion 5.5January 2012

All rights reserved. No part of this publication may be reproduced in any form or by any electronic or mechanical means,including photocopying and recording, without permission in writing from GE Intelligent Platforms, Inc.Disclaimer of Warranties and LiabilityThe information contained in this manual is believed to be accurate and reliable. However, GE Intelligent Platforms, Inc. assumesno responsibilities for any errors, omissions or inaccuracies whatsoever. Without limiting the foregoing, GE Intelligent Platforms,Inc. disclaims any and all warranties, expressed or implied, including the warranty of merchantability and fitness for a particularpurpose, with respect to the information contained in this manual and the equipment or software described herein. The entire riskas to the quality and performance of such information, equipment and software, is upon the buyer or user. GE IntelligentPlatforms, Inc. shall not be liable for any damages, including special or consequential damages, arising out of the user of suchinformation, equipment and software, even if GE Intelligent Platforms, Inc. has been advised in advance of the possibility of suchdamages. The user of the information contained in the manual and the software described herein is subject to the GE IntelligentPlatforms, Inc. standard license agreement, which must be executed by the buyer or user before the use of such information,equipment or software.Notice 2012 GE Intelligent Platforms, Inc. All rights reserved. *Trademark of GE Intelligent Platforms, Inc.Microsoft is a registered trademark of Microsoft Corporation, in the United States and/or other countries.All other brands or names are property of their respective holders.We want to hear from you. If you have comments, questions, or suggestions about our documentation, send them to the followingemail

Table of ContentsAbout This Guide . 1For New Users of Enhanced Failover: . 1For Existing Users of Enhanced Failover:. 1Terms You Should Know When Working with Enhanced Failover and LAN Redundancy . 2Components of Enhanced Failover . 3Active SCADA . 4Standby SCADA . 4Logical SCADA Name . 4iClient Connections . 5SCADASync.exe . 5SCADARoleMgr.exe . 5SCADASyncMonitor.exe . 5iFIXNotificationFG.exe and iFIXNotificationBG.exe . 5SCADASync.log and ScadaRoleMgr.log Files . 6Network Status Display (NSD) tags . 6Enhanced Failover Runtime Information (SCADASync) tags . 6What is Enhanced Failover? . 6What is my SCADA Role?. 8Summary of When Role Changes Occur . 8Introduction to Enhanced Failover . 9iii

Enhanced FailoverDifferences Between Enhanced Failover and Failover in Previous iFIX Releases . 9Updated Licensing . 10More Robust and Efficient Processing . 10Support for Database Synchronization . 10True Standby Node Support . 10Dedicated SCADA-to-SCADA Network for Improved Communications . 10Automatic Switching to Active SCADA . 11New NSD Tag Fields . 11Alarm Acknowledgement Synchronization Change . 11New Enhanced Failover Runtime Information Fields . 11Limitations of Enhanced Failover . 12General Limitations . 12Unsynchronized Items . 13Database Synchronization for Enhanced Failover . 14Synchronized Items . 14Items that Affect Database Synchronization Performance . 14File Synchronization . 15Alarm Management for Enhanced Failover . 15Understanding Enhanced Failover . 17What Happens when a Failover Occurs? . 17Alarm Handling for SCADA Servers . 18Logical Node Names . 18iv

Table Of ContentsI/O Drivers and Enhanced Failover . 19Alarm ODBC Service and Enhanced Failover . 20Proficy Historian and Enhanced Failover . 21Customizing the Synchronization Process with SCADASync.ini . 21Key Descriptions of SCADASync.ini . 22iFIX Notification and Enhanced Failover . 27Description of the Fields in the Notification Table . 27When iFIX Notification Displays the Message . 28How Notification Works, in More Detail . 29Configuration Examples: Enhanced Failover . 29Recovery Examples: Enhanced Failover Behavior . 31Scenario 1: Primary SCADA Unavailable . 32Scenario 2: Secondary SCADA Unavailable . 33Scenario 3: Both Primary and Secondary SCADA Unavailable . 34Scenario 4: iFIX Network to Primary SCADA from the Client Unavailable . 34Scenario 5: iFIX Network to Secondary SCADA from the Client Unavailable . 36Scenario 6: Dedicated Network Between Primary and Secondary Unavailable . 37Scenario 7: Complete Network Failure . 37Configuring a SCADA Server Pair for Enhanced Failover . 39Configuring Computers for Enhanced Failover . 39Preparation Checklist for Enhanced Failover . 40Checklist for Enhanced Failover Configuration . 42v

Enhanced FailoverConfiguring Computers for Enhanced Failover . 43Preparation Checklist for Enhanced Failover . 44Assigning Physical and Logical Node Names. 46Enabling Enhanced Failover . 47Configuring Data Transport for Options for Enhanced Failover. 50Data Sync Transport Options Dialog Box . 53Steps to Configure the Data Transports for Synchronization . 55Configuring iClients . 56How the iClient Works in Run Mode . 58Steps to Configure . 59Disabling the 1914 Error Message . 60Testing Your Enhanced Failover Configuration . 61Tips for Enhanced Failover Configurations . 62Synchronize the Clocks on the SCADA Servers. 62Identify Factors Affecting Performance . 63Monitoring Network Status . 65Monitoring Enhanced Failover Status and Initiating Manual Failover to the Standby SCADA65Triggering an Event on Failover . 66Network Status Server Fields. 66What are NSD Tags and NSS Fields? . 66How to View NSD Tags in iFIX . 67Zero-based NSD Fields . 67vi

Table Of ContentsOne-based NSD Fields . 68Field Descriptions . 68Example Uses of Network Status Server Fields . 75SCADA Failover . 76LAN Failover. 76Network Status Pictures in the iFIX WorkSpace . 76Custom Pictures with Logical and Physical Node Names . 77EDA and Network Server Status (NSS) Fields . 78Troubleshooting Enhanced Failover . 79Troubleshooting Checklist for Enhanced Failover Configuration . 83More Information on Network Card Usage . 84Tools for Troubleshooting . 85Log Files for Enhanced Failover . 86Error Messages for Enhanced Failover in iFIX . 88Monitoring SAC in Mission Control . 91Enhanced Failover Diagnostics with the SCADA Sync Monitor . 95Overview of the SCADA Node Synchronization History . 97Database Synchronization Status . 98Communication Status . 100Debug Log for Troubleshooting. 101Overall System Health . 102Global Memory Synchronization Status . 104vii

Enhanced FailoverRuntime Information Fields for Enhanced Failover . 104Example Uses of Runtime Information Fields for Enhanced Failover . 121Frequently Asked Questions about Enhanced Failover . 123Maintenance Mode . 125SCADA Synchronization Monitor . 126Maintenance Mode Steps . 127Security Area for Maintenance Mode . 127Maintenance Mode from Remote iClients . 128Using iFIX Security with Maintenance Mode . 128SCADASync Maintenance Mode Fields . 129Client Operations . 131Viewing Alarms on iClients. 131Reading Data in iFIX Pictures on iClients . 131Network Failure Detection on the iClient . 132Example of the iFIX Notification Window Under Normal Conditions . 133Example of the iFIX Notification Window when a Change Occurs . 133SCADAs With Enhanced Failover Detection on the iClient . 134viii

About This GuideThe Enhanced Failover e-book is intended for process control engineers, integrators, and developers responsiblefor designing and creating operator displays, and configuring the development and run-time environments. Themanual assumes familiarity with the process database, the iFIX WorkSpace, and the System ConfigurationUtility (SCU).For New Users of Enhanced Failover:This e-book contains the following sections to help you work with and understand the iFIX Enhanced Failoverfeatures: Terms for Working with Enhanced Failover Components of Enhanced Failover What is Enhanced Failover? What is my SCADA Role? Introduction to Enhanced Failover Understanding Enhanced Failover Configuring a SCADA Server Pair for Enhanced Failover Monitoring Network Status Troubleshooting Enhanced Failover Client Operations Maintenance ModeFor Existing Users of Enhanced Failover:If you are upgrading from a version of iFIX (before iFIX 5.0) with the previous Failover solution, be sure torefer to the Differences Between Enhanced Failover and Failover in Previous iFIX Releases section in this ebook and Enhanced Failover and Upgrading section in the Getting Started with iFIX e-book before you beginconfiguring or using the Enhanced Failover feature.A configuration checklist is provided in the Checklist for Enhanced Failover Configuration section as overview.1

Enhanced FailoverIf you are familiar with iFIX, this should get you started quickly in making your updates.The only changes between iFIX 5.0 and the current version of iFIX are the addition of the Enhanced FailoverRuntime Information (SCADASync) tags, and various server enhancements (that do not require anyconfiguration changes). For more information on the SCADASync tags, refer to the Runtime Information Fieldsfor Enhanced Failover section.Terms You Should Know When Working with Enhanced Failover andLAN RedundancyBefore you begin working with Enhanced Failover in iFIX you should familiarize yourself with the followingterms:2TermDescriptionEnhanced FailoverThe process of switching the active SCADA node from a waiting, standbySCADA node, when the active SCADA node becomes unavailable forprocessing data.Active SCADAThe fully functioning SCADA node in run mode. The active node sends theprocess database to standby node. All iClients retrieve their data and alarmsfrom the active SCADA. The active SCADA generates alarms.Standby SCADAThe “Idle” SCADA·node in run mode. Updates to the standby SCADA arebased on database synchronization updates pushed from the active node. Thestandby node replaces the concept of the backup node in previous versions ofiFIX, prior to iFIX 5.0.Physical NodeThe physical node (also called the local node) is the local iFIX node name,and should be unique within your iFIX network.Logical NodeA logical node is a pair of SCADA nodes configured to use EnhancedFailover. A client using a logical node obtains data from the active SCADAnode in the pair.

Enhanced FailoverTermDescriptionPrimary SCADAThe first node that you configure in your primary and secondary pair inconfigure mode. This is the node that goes active when you start iFIX, butmay not always be the active node.Secondary SCADAThe second node that you configure in your primary and secondary pair.SynchronizationA process that occurs on the active SCADA node, where the iFIX processdatabase and all files in the PDB folder changed from the last update arecopied to the standby node.The actual process name of the iFIX application that performs the databasesynchronization is SCADASync.exe. The ScadaRoleMgr.exe works in tandemwith the SCADASync.exe, and assigns the roles during failover.iFIX Client nodeOperators view process data received from a SCADA Server using a client(SCADA or iClient node).The client obtains data and alarms from the active SCADA node:A client automatically switches over to the newly active SCADA when afailover occurs.Any VBA script on the client continues to execute when a failover occurs. Ifthe VBA script is reading data while the failover occurs, the VBA script mayreturn an error.The Alarm Summary shows the same number of alarm and acknowledgestates after a failover occurs. The real-time trend shows some gap in the linechart.Components of Enhanced FailoverEnhanced Failover is the capability to switch over automatically to a standby SCADA Server when a failureoccurs. The switchover from the active to the standby SCADA Server occurs without user interaction, unless itis manually triggered. There are certain components that need to be configured and running to allow thisswitchover to occur.The following components are included in the iFIX Enhanced Failover configuration:3

Enhanced Failover Active SCADA Standby SCADA Logical SCADA iClient ConnectionsThe running components of iFIX Enhanced Failover system also include: SCADASync.exe Process SCADARoleMgr.exe Process SCADASyncMonitor.exe iFIXNotificationFG.exe and iFIXNotificationBG.exe Applications SCADASync.log and ScadaRoleMgr.log Files Network Status Display (NSD) tags (optional) Enhanced Failover Runtime Information (SCADASync) tags (optional)Active SCADAThe Active SCADA scans its database, communicates with the PLCs, and generates alarms. Periodically, itsends its database to the standby SCADA over the dedicated SCADA Synchronization network.Standby SCADAThe Standby SCADA is ready to take the place of the Active node if the need arises. SAC does not poll thedatabase or generate alarms on this node. Instead, the Standby SCADA receives database and alarm informationfrom the Active node.Logical SCADA NameA logical node is a pair of SCADA nodes configured for use with Enhanced Failover. A logical pair consists ofa Primary and a Secondary node. A client uses the logical node name to obtain data from the Active SCADAnode in the pair, and to communicate with the Active SCADA node. Each Enhanced Failover SCADA node(both Primary and Secondary) is defined by a unique physical name and a common logical name.The SCADA pair consists of a Primary node which is the preferred node in the pair, and a Secondary nodewhich is the backup node in the pair, each having a role/status. When Enhanced Failover is running, one nodewill be Active, and the other node will be in Standby. The Active node functions as a normal SCADA node.SAC is processing the database and alarms are being generated on the Active node. Additionally, the Active4

Enhanced FailoverSCADA node periodically sends database and alarm information to its partner, the Standby node.iClient ConnectionsiClient nodes allow operators to obtain data and alarms from the Active SCADA node. Clients must beconnected to the SCADA in “Active” mode to change data, acknowledge alarms, or write data to the PLC.It is required that you have a dedicated network connection for SCADA synchronization and a separateconnection for iFIX Client connections. iFIX Clients follow the Active SCADA. When a failover occurs, theClients are notified to connect to the new active SCADA. For more information on configuring iClients, refer tothe Configuring iClients sections.SCADASync.exeSCADASync.exe is the process name of the iFIX application that performs the synchronization.For more information on this process, refer to the What is Enhanced Failover? and What Happens when aFailover Occurs? sections.SCADARoleMgr.exeSCADARoleMgr.exe is a process that decides if the computer will be active or standby.For more information on this process, refer to the What is Enhanced Failover? and What Happens when aFailover Occurs? sections.SCADASyncMonitor.exeThe SCADA Sync Monitor (SCADASyncMonitor.exe) displays information about the primary and secondarySCADA Servers. You can use it for viewing diagnostic information about your Enhanced Failoverconfiguration, or for troubleshooting issues with your Enhanced Failover configuration. For more informationon this application, refer to the Enhanced Failover Diagnostics with the SCADA Sync Monitor section.iFIXNotificationFG.exe and iFIXNotificationBG.exeiFIX Notification (iFIXNotificationFG.exe and iFIXNotificationBG.exe) notifies a user on a Client that it isonly able to communicate with a standby SCADA node. You cannot write to a standby SCADA node, and astandby SCADA node does not generate any alarms. Since this limits what the operator can do, a modalmessage box appears informing the user about the condition until the active node becomes available again. Formore information, refer to the iFIXNotification.exe and Enhanced Failover section.5

Enhanced FailoverSCADASync.log and ScadaRoleMgr.log FilesFor Enhanced Failover, there are two additional log files available for troubleshooting. The SCADASync.logincludes messages that occur during the SCADA synchronization process. The ScadaRoleMgr.log includesmessages that occur during the active to standby node switchover. For more information on these log files, referto the Log Files for Enhanced Failover section.Network Status Display (NSD) tagsThe Network Status Display tag is a special tag residing on each networked node that displays diagnostic,failover, and network information. Networking in the SCU must be enabled to view these tags. These tags canbe added to your custom iFIX pictures. They also provide fields for manually triggering failovers:A SWITCHSCADAROLE and F SWITCHSCADAROLE. For more information, refer to the Network StatusServer Fields section.Enhanced Failover Runtime Information (SCADASync) tagsThe SCADASync tags are special tags consisting of runtime information for your Enhanced Failoverconfiguration. Enhanced Failover must be enabled in the SCU to view these tags. The SCADASync tags arevery helpful for troubleshooting your Enhanced Failover configuration, and can be added to your custom iFIXpictures. Many of these fields can be viewed from within the SCADA Sync Monitor; however, there are moreSCADASync fields than what is displayed in the SCADA Sync Monitor. Use these tags to obtain additionalinformation, for instance, regarding your data transports. For more information on these tags, refer to theRuntime Information Fields for Enhanced Failover section.What is Enhanced Failover?Enhanced Failover is the ability to define two SCADA nodes to function as one logical node. The logical nodeprovides data and alarms to its clients even if one of the SCADA nodes become inoperable. When you startiFIX on both nodes, one SCADA will be your active node, and the other will be your standby node.The active node continuously pushes a copy of the memory-based Process database (PDB) to the standby node.This process is called synchronization, by which real-time data such as setpoints, the tag database, and alarmsare synchronized between the SCADA node pair. The active node synchronizes its process database with thestandby node. SCADASync.exe is the process name of the iFIX application that performs the synchronization.SCADARoleMgr.exe is a process that decides if the computer will be active or standby.SCADASync.exe will use any available network connection for the synchronization; however, you shouldprioritize network usage to separate your real-time SCADA network from the synchronization network. It isstrongly recommended that you use a dedicated network between the primary and secondary SCADA nodes forsynchronization traffic. If the SCADA nodes are physically close to each other, then a crossover cable can be6

Enhanced Failoverused. Additionally, it is further recommended that the network components (LAN adapters, hubs, switches,cables, etc.) used for synchronization of the SCADA pair support a minimum 1 Gigabit Ethernet.The following figure shows an example of an Enhanced Failover configuration that includes two networks: adedicated network for SCADA-to-SCADA traffic, and a second network, LAN 1, which is for iFIX networking.Simple Enhanced Failover Example: One LAN and One Dedicated NetworkOperators view the process data received from a SCADA Server using an iClient. Should the active SCADAServer become unavailable, process data will become unavailable to the operator at the iClient workstation.Enhanced Failover increases the chance that data will continue to be available the iClient, despite a failure inthe active SCADA node component.Enhanced Failover allows you to connect an iClient to both the primary and secondary SCADA Server pair thatare connected to the same PLC(s). The iClient computer establishes and maintains the connections to both theprimary and secondary SCADA Server, either of which can be the active server or the standby server. When theactive SCADA Server fails

damages. The user of the information contained in the manual and the software described herein is subject to the GE Intelligent Platforms, Inc. standard license agreement, which must be executed by the buyer or user before the use of such information, equipment or software.

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