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Allen-Bradley ControlNet PLC-5 User Manual

Hot backup system
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Allen-Bradley
User Manual
ControlNet PLC-5
Hot Backup System
(Includes Cat. No. 1785-CHBM)
Table of Contents
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Summary of Contents for Allen-Bradley ControlNet PLC-5

  • Page 1 Allen-Bradley User Manual ControlNet PLC-5 Hot Backup System (Includes Cat. No. 1785-CHBM)
  • Page 2 In no event will the Allen-Bradley Company be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
  • Page 3 ,Q WKLV PDQXDO ZH GHVFULEH For information on: Refer to chapter/appendix: concepts for using a backup system in 1 - Backup Concepts for the ControlNet PLC-5 a ControlNet system; basic system Backup System architecture the hardware and software...
  • Page 4 ControlNet Repeater Installation Instructions 1786-2.7 For more information on any of the software components of the ControlNet PLC-5 backup system (e.g., RSLogix 5, RSLinx, and RSNetWorx), refer to the software documentation and online help for the individual software packages. Publication 1785-6.5.24 February 1999...

  • Page 5: Table Of Contents

    Table of Contents Chapter 1 Backup Concepts for the ControlNet PLC-5 Backup System Chapter Objectives ............... 1-1 Why Use a Backup System? ..........1-1 Basic System Architecture ............ 1-2 How the Backup System Works ........... 1-2 Qualification ..............1-3 Equivalence Checking ............ 1-3 Bumpless Transfer ............
  • Page 6 Appendix B Backup States Chapter Objectives ............... B-1 Invalid Backup State ............B-2 No Control Backup State ..........B-3 Primary Backup State ............. B-4 Lonely Primary Backup State ........B-4 Secondary Backup State ..........B-5 Backup State Transitions ............. B-5 Qualification ..............

  • Page 7: Backup Concepts For The Controlnet Plc-5 Backup System

    Chapter Objectives This chapter describes concepts for using a backup system with your programmable controller. In particular, this chapter describes the use of the ControlNet PLC-5 backup system, including its basic system architecture. Why Use a Backup System? The objective of any redundant system (i.e., backup system) is to...

  • Page 8: Basic System Architecture

    ControlNet from both processors. However, only data from the primary processor is used by the I/O adapter(s). In the case of the ControlNet PLC-5 backup system, there are several features to consider that, though common to many backup systems, are uniquely implemented in this particular system. Understanding these features and their functions will help you in the design and implementation of your backup applications.

  • Page 9: Qualification

    Backup Concepts for the ControlNet PLC-5 Backup System Qualification When bringing the secondary processor of a backup system online, it is important to ensure that it is in a state that will enable it to take over the control of the system in the event of a primary failure or switchover.

  • Page 10: Bumpless Transfer

    The ControlNet PLC-5 backup system allows you to choose synchronous program scan operation, as well on-demand crossloading of data table files you select. These options can greatly reduce the possibility of bumps during a processor switchover.

  • Page 11: Understanding The Controlnet Plc-5 Backup System Components

    PC with a 1784-KTCX15 card, or a laptop computer with a 1784-PCC card • other ControlNet devices, including HMI (optional) Software Components The basic ControlNet PLC-5 backup system includes the following software components: • RSLogix 5 programming software (Release 3.21 or later) •...

  • Page 12: Controlnet Backup Cartridge

    Understanding the ControlNet PLC-5 Backup System Components ControlNet Backup Cartridge Each ControlNet PLC-5 processor requires a 1785-CHBM/A ControlNet backup cartridge, inserted into the PLC-5 EEPROM memory cartridge slot, to enable backup functionality. The ControlNet backup cartridge contains EEPROM memory cartridge functionality (i.e., the cartridge can also be used as a standard PLC-5 EEPROM memory storage cartridge for the PLC-5 processor, with up to 100K of memory).

  • Page 13: Installing And Configuring Your Controlnet Plc-5 Backup System

    Chapter Installing and Configuring Your ControlNet PLC-5 Backup System 7KLV FKDSWHU RXWOLQHV WKH VWHSV \RX PXVW SHUIRUP WR LQVWDOO WKH EDFNXS Chapter Objectives V\VWHP FRPSRQHQWV DQG WR VXEVHTXHQWO\ FRQILJXUH WKHP WR FUHDWH D IXQFWLRQLQJ EDFNXS V\VWHP Installing the Hardware Before you begin, be sure that you have all of the required hardware components, as listed in Chapter 2.

  • Page 14: Configuring Your Backup System

    Configuring With a Single Control Application This section assumes that you have already developed your control application and have loaded it onto a single ControlNet PLC-5 processor (i.e., a non-backup system). Throughout this section, we will refer to this processor as the first processor. Furthermore, we assume that you have a second processor installed, powered on, and in its default state.
  • Page 15 Reconfigure ControlNet I/O on the First PLC Processor Reconfigure all ControlNet I/O adapters and modules that will be in your ControlNet PLC-5 backup system by changing their ControlNet connection from Exclusive Owner (default) to Redundant. 1. Launch RSNetWorx for ControlNet.
  • Page 16 Installing and Configuring Your ControlNet PLC-5 Backup System The Receive Scheduled Message dialog appears. The Node Number field is already filled in for you. This number indicates the node number from which you will receive the Receive scheduled message. In your ControlNet backup system, the odd node will receive the message from the even node, and vice versa.
  • Page 17 Installing and Configuring Your ControlNet PLC-5 Backup System 8. Record the Send and Receive message numbers from the odd processor node below: Send message number:__________ Receive message number:__________ You will use these numbers later in the configuration process. Configure ControlNet I/O on the Second PLC Processor...
  • Page 18 Installing and Configuring Your ControlNet PLC-5 Backup System 3. In the Processor Node field, enter the node number of the first processor. 4. Click on the Online button to connect to the processor. 5. When prompted, click on OK to confirm that you wish to complete the upload.

  • Page 19: Configuring With Differing Applications

    Installing and Configuring Your ControlNet PLC-5 Backup System Create and Download the Project for the Second PLC Processor The next step in configuring your system is to duplicate the fully-configured project from the first processor and apply it to the second processor.
  • Page 20 Reconfigure ControlNet I/O on the First PLC Processor Reconfigure all ControlNet I/O adapters and modules that will be in your ControlNet PLC-5 backup system by changing their ControlNet connection from Exclusive Owner (default) to Redundant. 1. Launch RSNetWorx for ControlNet.
  • Page 21 Within your backup system, you must use RSNetWorx to set up the send and receive scheduled messages that allow handshaking to occur between the two ControlNet PLC-5 processors that comprise your backup system. For each of the processors comprising a backup system, you must create two scheduled peer-to-peer messages: one Send and one Receive.
  • Page 22 Reconfigure ControlNet I/O on the Second PLC Processor Reconfigure all ControlNet I/O adapters and modules that will be in your ControlNet PLC-5 backup system by changing their ControlNet connection from Exclusive Owner (default) to Redundant. 1. Launch RSNetWorx for ControlNet.
  • Page 23 Installing and Configuring Your ControlNet PLC-5 Backup System 3-11 Configure the Hot Backup Parameters 1. Launch RSLogix 5. 2. From the Comms menu, choose System Comms... The System Options dialog appears, with the System Communications tab selected. 3. In the Processor Node field, enter the node number of the first processor.

  • Page 24: Advanced Configuration Options

    Advanced Configuration Options The procedures in the previous sections outlined the steps required to configure a basic ControlNet PLC-5 backup system. In addition, there are other options you can configure for the backup system. In addition to the information provided here, you can find specific details on these features in the appendices of this manual.

  • Page 25: Synchronous And Asynchronous Program Scanning

    Installing and Configuring Your ControlNet PLC-5 Backup System 3-13 Synchronous and Asynchronous Program Scanning One of the most important considerations when implementing a backup system is the effect of divergence on the system. Divergence occurs when the primary and secondary controllers are running their applications and scanning the I/O asynchronously to each other.

  • Page 26: Equivalence Checks

    3-14 Installing and Configuring Your ControlNet PLC-5 Backup System Note: When you choose Synchronous mode, you will have to enter a Maximum Program Scan Time as well. Before selecting Synchronous mode, enter a value into the Max Program Scan Time field.

  • Page 27: Crossloading

    Installing and Configuring Your ControlNet PLC-5 Backup System 3-15 Crossloading You can perform data table crossloading on demand. While both PLC processors are running, you can initiate a crossload from either the primary or secondary processor. You can perform a crossload on the following data file types: •...

  • Page 28: Status

    3-16 Installing and Configuring Your ControlNet PLC-5 Backup System Status You can view system status from the Status tab of the ControlNet Hot Backup screen. The CBC Module LEDs section mirrors the display of the LEDs on the 1785-CHBM module which is currently online.

  • Page 29: Processor Editing Considerations

    Processor Editing Considerations There are some considerations you should be aware of when editing the processor of a ControlNet PLC-5 backup system. Editing, in this context, refers to any changes you make to the program files, data table structure, force tables, and status file. Edits that you make to one processor are not automatically transferred to the other processor.
  • Page 30 3-18 Installing and Configuring Your ControlNet PLC-5 Backup System Publication 1785-6.5.24 February 1999...

  • Page 31: Monitoring And Troubleshooting Your Controlnet Plc-5

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  • Page 32: Using The 1785-Chbm Cartridge Status Indicators

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  • Page 33: Troubleshooting The Invalid Backup State

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  • Page 34: Troubleshooting Qualification Major Faults

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  • Page 35: Troubleshooting Qualification Crossloads

    Monitoring and Troubleshooting Your ControlNet PLC-5 Backup System ,I WKH GDWD WDEOH VWUXFWXUHV DUH WKH VDPH EHWZHHQ WKH WZR SURFHVVRUV Troubleshooting Qualification GDWD WDEOH FURVVORDGV DXWRPDWLFDOO\ RFFXU GXULQJ TXDOLILFDWLRQ Crossloads 6KRXOG WKH 4XDOLILFDWLRQ 'DWD 7DEOH FURVVORDGV IDLO WKH SURFHVVRU PDMRU IDXOWV 5HIHU WR $SSHQGL[ & IRU PRUH LQIRUPDWLRQ RQ GDWD...
  • Page 36 Monitoring and Troubleshooting Your ControlNet PLC-5 Backup System Word Definition Reason code indicating why the processor is in the Invalid backup state. This word is constantly updated until the processor is no longer in this state. Valid values include: • 0 - In valid state •...
  • Page 37 Monitoring and Troubleshooting Your ControlNet PLC-5 Backup System Word Definition 15-19 reserved 20-24 These words are functionally the same as words 10 through 14. The difference is that words 20 through 24 display the current internal PLC-5 processor state of these configuration parameters. When in Run mode, the PLC-5 processor will continuously update words 20 through 24.
  • Page 38 Monitoring and Troubleshooting Your ControlNet PLC-5 Backup System Word Definition Perform On-Demand Crossload. You can specify whether to crossload timers, counters, PID files, or user-defined files (configured in words 55, 56, 57, and 58 of the ControlNet Backup Configuration and Status file) by setting appropriate bits in this word.
  • Page 39 Monitoring and Troubleshooting Your ControlNet PLC-5 Backup System Word Definition Qualification Crossload Time. The time (in ms) it takes to crossload the entire data table from the primary processor to the secondary processor. This value is overwritten each time the processor goes through qualification.
  • Page 40 4-10 Monitoring and Troubleshooting Your ControlNet PLC-5 Backup System Qˆiyvph‡v‚Ã &'$%$!#ÃAri…ˆh…’Ã...

  • Page 41: Specifications

    Appendix Specifications 7KH IROORZLQJ VSHFLILFDWLRQV DUH IRU WKH &+%0 FDUWULGJH Specifications Description: Value: Memory Module 1785-CHBM Capacity 100K words Type Nonvolatile Write Protection By removing the jumper Weight 70.875g 2.5 oz. Environment Operating Temperature 0° to 60° C (32° to 140° F) Storage Temperature -40°...
  • Page 42 Specifications Qˆiyvph‡v‚Ã &'$%$!#ÃÃAri…ˆh…’Ã...

  • Page 43: Backup States

    Appendix Backup States 7KLV $SSHQGL[ GHVFULEHV WKH SRVVLEOH EDFNXS VWDWHV DQG EDFNXS VWDWH Chapter Objectives WUDQVLWLRQV RI WKH 3/& &RQWURO1HW EDFNXS V\VWHP 7KHUH DUH IRXU PDLQ EDFNXS VWDWHV ‡ ,QYDOLG ‡ 1R &RQWURO ‡ 3ULPDU\ DQG /RQHO\ 3ULPDU\ • Secondary QPX@SVQ IPÃ768FVQ 86S9...
  • Page 44 Backup States ,QYDOLG %DFNXS 6WDWH :KHQ DQ LPSURSHU EDFNXS FRQILJXUDWLRQ H[LVWV WKH 3/& &RQWURO1HW EDFNXS V\VWHP JRHV LQWR WKH ,QYDOLG EDFNXS VWDWH %RWK WKH 3ULPDU\ DQG 6HFRQGDU\ /('V RQ WKH &+%0 FDUWULGJH DUH VROLG UHG ZKHQ WKH V\VWHP LV LQ WKLV VWDWH DQG WKH 4XDOLILHG DQG 6\QFKURQRXV /('V DUH RII ,I \RX VZLWFK WKH V\VWHP WR 5XQ PRGH ZKLOH LQ WKH ,QYDOLG EDFNXS VWDWH D PDMRU IDXOW RFFXUV 5HIHU WR &KDSWHU IRU GHILQLWLRQV RI WKH PDMRU IDXOW FRGHV...

  • Page 45: Invalid Backup State

    Backup States ‡ RQH RI WKH RSWLRQDO FRQILJXUDWLRQ SDUDPHWHUV LQ WKH &RQWURO1HW %DFNXS &RQILJXUDWLRQ DQG 6WDWXV )LOH LV LQYDOLG WKH IROORZLQJ RSWLRQDO SDUDPHWHUV DUH FKHFNHG 2SHUDWLRQDO PRGH LQYDOLG LI QRW HTXDO WR RU (TXLYDOHQFH FKHFNV LQYDOLG LI JUHDWHU WKDQ [I 'HVLJQDWHG SULPDU\ LQYDOLG LI QRW HTXDO WR RU 0D[LPXP SURJUDP VFDQ WLPH LQYDOLG LI JUHDWHU WKDQ [ 187 DQG V\QFKURQRXV RSHUDWLRQDO PRGH...

  • Page 46: Primary Backup State

    Backup States Primary Backup State When a PLC-5 ControlNet backup system is in Run mode, and is actively controlling all of the system outputs, it is in the Primary backup state. The Primary LED is green, either blinking or solid; the Secondary LED is off.

  • Page 47: Secondary Backup State

    Backup States Secondary Backup State When a PLC-5 ControlNet backup system is in Run mode, and is not actively controlling the system outputs, it is in the Secondary backup state. The Secondary LED is solid yellow, the Primary LED is off, and the Qualified LED is solid green.
  • Page 48 Backup States Qualification: From the No Control State to the Secondary State The backup state transition from No Control backup state to Secondary backup state occurs when the PLC-5 system transitions from Program mode to Run mode, and the partner PLC-5 processor is in the Primary backup state and is communicating with this PLC-5 processor.
  • Page 49 Backup States • Equivalence checks The PLC-5 ControlNet backup system does not download the entire memory from the primary system to the secondary system; there are certain data table values that are crossloaded. Areas such as the program files and data table structures may be different between the primary and secondary system.
  • Page 50 Backup States ControlNet Backup Configuration and Status file - This checksum is only calculated when the PLC-5 system goes through qualification. Since this checksum cannot change when the PLC-5 system is in Run mode, this checksum does not change after qualification. The ControlNet Backup Configuration and Status File checksum is only calculated on the first 3 words of the ControlNet Backup Configuration and Status File.
  • Page 51 Backup States You can selectively enable equivalence checking for none, some, or all of the 6 of the equivalence check areas, with one exception: the Program File Structure and Program File checksum is dependent on the Data Table Structure. Thus, if you select the Program File Structure and Program File equivalence check, you should also select the Data Table Structure equivalence check.
  • Page 52 B-10 Backup States All elements of all data table files are crossloaded in the Qualification Data Table crossload, with the exception of the following files. These files cannot be crossloaded because they contain processor-specific configuration and status information. Status File ControlNet Backup Configuration and Status File ControlNet Data Input File (DIF) ControlNet Data Output File (DOF)
  • Page 53 Backup States B-11 The Qualification State Data Table crossload reads data table values from the primary PLC-5 system and writes these values to the qualifying PLC-5 system. The State Data Table crossload only crossloads specific parts of the data table. There are 4 different parts of the data table that are crossloaded: Timer Accumulators Counter Accumulators...
  • Page 54 B-12 Backup States Reasons for Qualification Major Fault While qualification should complete without any problems, there are several checks performed during qualification that can cause it to fail. When the qualification procedure fails, a major fault is declared. Qualification could fail under any of the following circumstances or conditions: •...
  • Page 55 Backup States B-13 If the even ControlNet node is the only processor to pass qualification, it is the primary processor. However, should the odd ControlNet node pass qualification, a switchover immediately occurs, the odd ControlNet node becomes the primary processor, and the even ControlNet node becomes the secondary processor.
  • Page 56 B-14 Backup States Unqualified Switchovers Unqualified Switchovers occur when the primary processor of a qualified PLC-5 ControlNet backup system is no longer in Run mode, or when the secondary processor loses its peer-to-peer handshake connection with the primary processor. The secondary processor then does a switchover to become a stand-alone primary processor.
  • Page 57 Backup States B-15 Since the peer-to-peer handshake connection is one NUT, it only takes up to one NUT for the primary system to indicate to the secondary system that a switchover must occur. There is up to 5ms of processing on each processor to get the switchover indication from the primary system to the secondary system.
  • Page 58 B-16 Backup States Qˆiyvph‡v‚Ã &'$%$!#ÃAri…ˆh…’Ã...

  • Page 59: Data Table Crossloading

    Appendix Data Table Crossloading 7KLV DSSHQGL[ SURYLGHV \RX ZLWK UHIHUHQFH LQIRUPDWLRQ RQ WKH GDWD Chapter Objectives WDEOH FURVVORDGLQJ IHDWXUH Data Table Crossloading Data table crossloading is a feature you can enable to minimize the bump in system outputs when a processor switchover occurs. This feature is most useful when identical PLC-5 processors are used in the backup system.

  • Page 60: On-Demand Data Table Crossloads

    Data Table Crossloading In addition to the crossloading mentioned above, there is Automatic data table crossloading, occurring at the time of qualification, which transfers data table values from the primary processor to corresponding data table locations on the secondary processor. This ensures that when a secondary processor becomes qualified, that processor is immediately ready to take over control of the outputs should a switchover occur.
  • Page 61 Data Table Crossloading • Timer Accumulators When Timer Accumulators are crossloaded during the On-Demand data table crossload, only the Accumulator subelements of the Timer structures are crossloaded. Crossloading only the Accumulator subelements of the Timer structures allows the secondary processor to match the Accumulator values in the primary processor without corrupting the control bit subelements of the Timer structures in the secondary processor.
  • Page 62 Data Table Crossloading The two individual files as well as the range of files you select are crossloaded, regardless of file type. There are some notable exceptions; the following files are not be crossloaded even when you select them: Output Image File (File 0) Input Image File (File 1) System Status File (S2) ControlNet Data Output File (DOF)
  • Page 63 Data Table Crossloading The On-Demand data table crossload operations that get performed depend on the value written into the On-Demand Crossload Command word. The 4 least significant bits of the On-Demand Crossload Command word are defined for the 4 different On-Demand data table crossload operations.
  • Page 64 Data Table Crossloading All elements of all data table files are crossloaded in the Qualification data table crossload with the exception of the following files. These files cannot be crossloaded because they contain processor-specific configuration and status information. • System Status File (S2) •...

  • Page 65: Data Table Crossload Time

    Data Table Crossloading Data Table Crossload Time It may take many seconds for any of the above instances of data table crossloading to finish. The time it takes to do the data table crossload primarily depends on the amount of data table data to be crossloaded. The data table crossload is performed using the unscheduled bandwidth of the ControlNet channel.

  • Page 66: Data Table Crossload Diagnostics

    Data Table Crossloading Data Table Crossload Diagnostics There are some words reserved in the ControlNet Backup Integer File for data table crossload diagnostics. First, there is a data table crossload active word (word 52 in the ControlNet Backup Integer file). This word is non-zero whenever a data table crossload is active. This word is zero whenever a data table crossload is inactive.

  • Page 67: Program Synchronization

    Chapter Objectives SURJUDP V\QFKURQL]DWLRQ IHDWXUH Program Synchronization Both processors in a ControlNet PLC-5 backup system execute their own program logic. You can configure the ControlNet PLC-5 backup system to have either Asynchronous program scans or Synchronous program scans. Asynchronous mode allows the program scans on the two processors to run as if they were stand-alone processors.

  • Page 68: Determining Which Mode To Use

    Program Synchronization Determining Which Mode to Use Determining whether to select Asynchronous mode or Synchronous mode depends on your application. If the program logic is completely different between the two processors, it is appropriate to select Asynchronous mode. Also, if the program scan time frequently bumps out from a small value to a very large value so that the configured Maximum Program Scan Time is too large for the application, it would be appropriate to select Asynchronous mode.
  • Page 69 Program Synchronization Adjusted Maximum Program Scan Time The Maximum Program Scan Time parameter you enter for Synchronous mode gets adjusted before being used by the ControlNet PLC-5 Backup system. The Adjusted Maximum Program Scan Time is equal to the smallest integer number of NUT’s whose time value is greater than or equal to the Maximum Program Scan Time parameter.
  • Page 70 Program Synchronization Qˆiyvph‡v‚Ã &'$%$!#ÃÃAri…ˆh…’Ã...

  • Page 71: Application Guidelines

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  • Page 72: What Information Should Be Transferred

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  • Page 73: When Should The Information Be Transferred

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  • Page 74: Performance Considerations

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  • Page 75: Comparison To The 1785-Bcm System

    Appendix Comparison to the 1785-BCM System 7KLV DSSHQGL[ SURYLGHV \RX ZLWK D FRPSDULVRQ EHWZHHQ WKH Chapter Objectives &RQWURO1HW 3/& EDFNXS V\VWHP DQG WKH %&0 EDFNXS V\VWHP /LNH WKH %&0 VFKHPH WKH &RQWURO1HW 3/& EDFNXS V\VWHP PDNHV Comparison to the BCM System XVH RI D SULPDU\ DQG D VHFRQGDU\ SURFHVVRU ZKHUH ERWK WKH SULPDU\ DQG VHFRQGDU\ SURFHVVRUV VLPXOWDQHRXVO\ H[HFXWH WKHLU FRQWURO ORJLF +RZHYHU WKHVH WZR EDFNXS VFKHPHV GLIIHU LQ PDMRU ZD\V...
  • Page 76 Comparison to the 1785-BCM System $QRWKHU GLIIHUHQFH LQ WKH WZR EDFNXS V\VWHPV LV WKDW WKH &RQWURO1HW EDFNXS V\VWHP GRHV 127 SURYLGH D &XVWRPHU 5HOD\ %HFDXVH RI WKH V\VWHP DUFKLWHFWXUH LW LV SRVVLEOH ZLWK WKH &RQWURO1HW EDFNXS V\VWHP WR KDYH 00, GHYLFHV DFWLYHO\ FRPPXQLFDWLQJ ZLWK ERWK WKH 3ULPDU\ DQG 6HFRQGDU\ 3/&V Qˆiyvph‡v‚Ã...
  • Page 77 Publication 1785-6.5.24 February 1999...
  • Page 78 Allen-Bradley, a Rockwell Automation Business, has been helping its customers improve productivity and quality for more than 90 years. We design, manufacture and support a broad range of automation products worldwide. They include logic processors, power and motion control devices, operator interfaces, sensors and a variety of software.

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