TSL TM1 Mk3+ Istruzioni operative

TM1 Mk3+ Redundancy:

Installation and Operation Guide

Version History

Issue Date Change Details

1 05/11/21 First draft

2 23/05/22 Second draft

3 17/06/22 Third draft

4 30/06/22 Fourth draft

5 12/04/23 Fifth draft

Contents

Introduction ....................................................................................................................................................5

Terminology ................................................................................................................................................5

System overview.........................................................................................................................................6

Primary and Backup controllers ................................................................................................. 6

Active system controller ............................................................................................................ 6

Writing configurations ............................................................................................................... 6

Connecting to the system .......................................................................................................... 6

Ethernet .................................................................................................................................... 6

Backup Link................................................................................................................................ 8

GPIO and Serial Connections...................................................................................................... 9

What do I need to build a redundant system? .........................................................................................11

Main hardware requirements .................................................................................................. 11

Direct Link Cable...................................................................................................................... 12

TallyMan Redundancy Panel (TMRP)........................................................................................ 12

Hardware installation ...................................................................................................................................13

TM1-MK3+ ................................................................................................................................................13

Direct link and Ethernet ........................................................................................................... 13

IP addressing ........................................................................................................................... 13

TMRP.........................................................................................................................................................16

Mounting................................................................................................................................. 16

Power...................................................................................................................................... 16

Connections............................................................................................................................. 16

Open Collector Connections and Circuit ................................................................................... 17

Setup ....................................................................................................................................... 17

Software installation.....................................................................................................................................23

Opening the TallyMan software ...............................................................................................................23

Creating a new configuration ...................................................................................................................24

Modifying an existing configuration .........................................................................................................28

Operation......................................................................................................................................................31

TM1-Mk3+ Front Panel.............................................................................................................................31

TM1-MK3+ Display – Standalone Mode ................................................................................... 31

TM1-MK3+ Display – Redundancy Mode.................................................................................. 31

Status Descriptions ...................................................................................................................................32

Redundancy Menu....................................................................................................................................33

TMRP Connections................................................................................................................... 34

Normal Operation.....................................................................................................................................35

TMRP Operation .......................................................................................................................................36

Failover Mode ...........................................................................................................................................37

Automatic Mode...................................................................................................................... 38

Manually changing the Active Unit...........................................................................................................39

Failover Events..............................................................................................................................................41

Replacing a System Controller..................................................................................................................46

Primary System Controller ....................................................................................................... 46

Backup System Controller ........................................................................................................ 47

TMRP....................................................................................................................................... 47

Introduction

TallyMan TM1 MK3+ redundancy allows TallyMan control systems to continue to operate when an

unexpected issue occurs, or a system controller needs to be taken offline for maintenance. It operates on

an A->B failover basis: if a failover event occurs then the system will automatically deactivate its Primary

controller and activate the Backup controller so that operations can continue. This type of failover system

offers protection from events such as power failure, network interruptions or system failure and greatly

improves the ability to maintain operations in the occurrence of a failover event.

The TallyMan redundancy system has both automatic and manual failover modes, meaning that an

operator can change the failover mode from auto to manual to perform maintenance tasks with minimal

disruption to operation.

Terminology

The table below lists the terms used in this guide, along with the abbreviations that appear on the

TallyMan Redundancy Panel (TMRP) buttons.

Term

TMRP Term

Meaning

Primary

Primry

The unit that is expected to be in use during normal operation. Even if it fails over to the Backup

unit, it is still called the Primary.

Backup

The unit that is ready to take over from the Primary in the event of a failover. Even if it becomes

Active, it is still called the Backup, since it is assumed that normal service will eventually be

restored, and the Primary will take control again.

Active

The Active TM1 (either Primary or Backup) has functional control over the redundancy system.

Standby

Stndby

The Standby TM1 is working correctly and ready to take over functional operations when

required. Note the ability to take over control is determined by other settings within the system

such as the Failover Mode.

Activating

Acting

A TM1 that is in the process of becoming Active.

Deactivating

Deactg

A TM1 that is in the process of Deactivating to enter Standby mode.

Unavailable

Unvail

A TM1 that is not available to be either Active or in Standby mode.

Failover Mode

F.Over

The Failover mode, changes between Auto and Manual failover operations.

Automatic

Failover

Auto

Automatic Failover mode – The system monitors itself to determine if a failover event has

occurred and then implements the failover action.

Manual Failover

Manual

Manual Failover mode – The user is free to change over the Active unit manually; while in this

mode the system will not failover automatically.

Auto Armed

Auto: Armed

Failover mode is in Auto AND the system is ready to act in the occurrence of a failover event.

This is only available if the Primary is Active.

Auto Triggered

Auto: Trggd

Failover mode is in Auto AND the system has triggered a Failover action. The Backup TM1 is the

Active unit.

Auto Unavailable

Auto: Unavbl

Failover mode is in Auto. However, the system is not able to act in the occurrence of a Failover

event. This could be due to a physical connection issue, network issues or errors in the system.

System overview

This section explains the basic principles behind a redundant system.

Primary and Backup controllers

The Primary system controller is the main system controller and during normal operation will perform the

operational functionality. Once designated as the Primary during configuration, the system controller will

always be the Primary within the system until the configuration changes.

The Backup system controller is also designated during configuration and is always the Backup system

controller in the redundancy system. In normal operation the Backup will operate in Standby mode

whereby it is continuously synchronised with the Primary and monitors the Primary’s health. In the event

of a Failover, the Backup will assume control by Deactivating the Primary and becoming Active.

Note that the synchronisation is from Primary to the Backup. Once the Backup becomes Active then the

Primary will not remain synchronised with the Backup. Restoring the Primary to be the Active system

controller is a Manual operation, at this point the Backup will return to Standby mode and synchronise

itself with the Primary again.

Active system controller

The Active status denotes the system controller that is currently actively controlling the system. Either

the Primary or Backup can be active, only one can be Active at any time. Note the Primary is always the

Primary and the Backup is always the Backup, it is the Active state that determines which unit is currently

in control.

Writing configurations

When using the TallyMan configuration software, unless connected to the system, all configuration is

performed offline. Configuration files are always written to the Primary system controller using the NIC1

IP address as defined in the configuration. Upon receiving a new configuration, the Primary will load the

configuration file and reconfigure itself accordingly to establish which mode to run in and whether it is

designated as Primary or Backup. Once it has determined it is the Primary and finished loading, it will

then automatically write the configuration to the Backup unit, which will then go through the same

process to determine its mode and function.

Connecting to the system

Each system controller has two Ethernet NICs and can thus support two separate networks. Writing

configurations and connecting to the system is performed using the static IP address assigned to these

NICs. You must use NIC1 to connect to the system.

Within a redundancy system there is also a virtual IP address assigned to each NIC. This is used for

communications to equipment outside of the redundancy ‘bubble’.

Ethernet

Each TM1-Mk3+ unit can support two separate networks to perform control functions. For a redundant

system, both units must use the same subnets for each NIC. For example, if NIC 1 of the Primary TM1-

Mk3+ is on the subnet 192.168.10.XXX then the Backup unit’s NIC 1 must also use the subnet

192.168.10.XXX. See IP Address and VIP assignment example.

Each NIC port also hosts a Virtual IP address (which must be on the same subnet as the permanent IP

address) that is defined in the TallyMan configuration software (as described below). This is different to

the static IP addresses that are configured via the front panel of each unit and is used as part of the

redundancy operations.

The NIC 1 port is the uppermost Ethernet port on the rear of the TM1-MK3+ system controller. NIC 1

supports the redundancy system and is used for communications between the units. Connection to

external equipment can be via either of the NIC ports.

Virtual IP Addresses (VIPs)

The system utilises VIPs to simplify any external communications to either TSL equipment (such as control

panels or GPIO expansion) and to third-party equipment (such as routers and switchers). The VIPs (one

per NIC) are dynamically applied to the currently active unit. In the event of a failover, either manual or

automatic, the VIP is removed from the previously active unit and then applied to the newly active unit.

This mechanism allows for an almost seamless transition in the event of a failover, with the same IP

address being used so that external equipment can continue to communicate to the TallyMan control

system.

The VIP mechanism has a failsafe to prevent both TM1-Mk3+ system controllers using the same address

at the same time. In most cases, the VIP is disabled from the deactivating unit then enabled to the

activating unit. The activating unit will not enable the VIPs until it can be certain the VIPs have been

disabled on the deactivating unit. If this procedure cannot be completed, the Backup unit can shut down

the Primary unit to ensure that the VIPs are not being used.

IP Address and VIP assignment example

The table below shows some example settings for IP addresses and VIPs on TallyMan equipment in a

redundant setup.

Unit

NIC 1

NIC 2

VIP

Primary

192.168.10.1

192.168.20.1

192.168.10.4

Backup

192.168.10.2

192.168.20.2

192.168.10.5

TMRP

192.168.10.3

N/A

Under normal operation, the Primary is Active, and hosts the Virtual IP addresses:

During a transition, the Primary is Deactivating, the Backup is Activating, and there is no direct

connection via the VIP:

After failover, the Backup unit is Active and hosts the Virtual IP Addresses, and the Primary unit is in

Standby:

During Backup operation, the Backup unit is Active and hosts the Virtual IP addresses; the Primary unit is

Remotely Shutdown:

Backup Link

The Primary and Backup system controllers communicate via two links, the Direct Link cable and the NIC

1 Ethernet port (labelled as IP Link). These two-communication links allow for the monitoring between

the Primary and Backup; both are required for a redundant system to work correctly. The status of both

communication links between the system controllers is displayed on the front panel of the TM1-MK3+

when it is configured in redundancy mode:

GPIO and Serial Connections

The GPIO and Serial connections of TM1 in a redundant system can be setup in the following ways:

•Using a VIP connection (preferred)

•Using a Changeover device

Using a VIP connection

In this approach, the Serial and GPIO are moved outside of the redundancy ‘bubble’ and interface to the

system via the VIPs. To achieve this, we use a GPIO expansion device such as the TSL ESP-1R+. This

expansion device will then connect to the system via the VIP address and communicate with the system

without any requirement to know which TM1 is currently Active.

Serial devices can be set up in a similar way using an Ethernet-to-Serial convertor. The convertor will

communicate to the TallyMan system using a VIP address and continue to operate after a Failover event

has occurred.

The diagram below shows the connection of external GPIO and Serial devices to the TallyMan

Redundancy system when the Primary is Active and hosting the Virtual IP addresses:

The diagram below shows the connection of external GPIO and Serial devices to the TallyMan

Redundancy system when Backup is Active and hosting the Virtual IP addresses:

Using a Changeover device

An alternative approach is to use a changeover device such as the TSL SW2x1 changeover frame. The

required GPIO and Serial connections are routed thorough the changeover device from both the Primary

and Backup TM1 units. The output of the changeover device is then connected to the equipment as

required. The operation of the changeover unit is controlled by the GPO of a TMRP that will reflect the

status of the current system. The connections from the Active system controller will then be routed to

the output of the changeover unit and then on to any third-party devices as required.

The diagram below shows GPIO and Serial connections connected to third-party equipment via a

changeover unit, controlled by the GPIO system status of the TMRP. Multiple TMRP units can be

paralleled for changeover control redundancy:

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