Title Goes ASSET MANAGEMENT MAXIMIZING UPTIME: BUILDING A FAULT-TOLERANT FACTORYTALK ASSETCENTRE SYSTEM
ASSET MANAGEMENT Introduction FactoryTalk AssetCentre software has proven to be the industry standard in asset management of automation controls plant wide. In the event of a hardware failure on the server running FactoryTalk AssetCentre, there is a risk of production down time. One way to mitigate this risk is to deploy FactoryTalk AssetCentre on a hardware redundant server system running Marathon Technologies everrunft fault-tolerant software. This whitepaper outlines a solution that provides users with a highavailability, fault-tolerant server system to host their FactoryTalk AssetCentre application. Marathon Technologies everrunft Overview The Marathon Technologies everrunft management software runs on two server computers running in tandem. These machines are called CoServers. The Marathon Technologies everrunft software creates a virtual server from the CoServer pair. The CoServer systems require standard dual processors and a pair of hyper-threaded or dual core Intel processor server-class computers running Microsoft Windows Server 2003. These computers, which coordinate the fault-tolerant operations, are connected by dual gigabit Ethernet networks. No proprietary hardware is required. Application software, like the FactoryTalk AssetCentre system server, is installed on the virtual server. The Marathon Technologies solution only requires a single Microsoft Windows 2003 Server license for the fault-tolerant virtual server where you run FactoryTalk AssetCentre. Additionally, you must activate Microsoft Windows 2003 Server on each of the CoServers and the virtual server. The Virtual Server The virtual server appears on the network as a standard Windows 2003 server. Applications are installed and run just as they would be on a physical Windows server, but because they are running in a fault-tolerant environment, they are protected from hardware and many operating system failures. The virtual server can be accessed from either CoServer using a keyboard, mouse, and monitor connected to either CoServer as outlined in the Getting Started with everrun FT Guide or directly using Windows remote desktop over the network. Virtual server system backup is also simplified using Marathon Technologies everrunft to host your FactoryTalk AssetCentre server, using a Marathon Virtual Disk as outlined in the Virtual Server Setup section of the Marathon Technologies everrunft Installation Guide. This virtual disk drive can easily be backed up to a remote location or removable media. This is another great feature of FactoryTalk AssetCentre built on Marathon Technologies everrunft. 2 P age
MAXIMIZING UPTIME The CoServers A CoServer is a physical server configured using Microsoft Windows and the everrunft software. At this point you are probably asking yourself, what is a CoServer? A CoServer, in Marathon Technologies terminology, is a physical server configured using a licensed version of Microsoft Windows Server 2003 and Marathon Technologies everrunft. The Marathon everrun FT software, running on these two CoServers, creates a single virtual machine, running a single Windows system. The Marathon everrunft software runs between a single copy of Windows and all of the hardware (much like RAID controller software runs between Windows and drives, or the way BIOS runs between Windows and the hardware). The everrunft software pairs up all devices to create fault tolerance, and to create a single device in the virtual machine for each pair. For disks, this is exactly identical to what a RAID controller does for RAID1 drives. The way in which fault tolerance is provided depends on the device. For example, for the keyboard or mouse, everrunft will take inputs from a mouse and keyboard connected to either CoServer and forward them as inputs for the one mouse and one keyboard which Windows thinks it has in the virtual server. Ethernet ports are essentially teamed up to look like one Ethernet port in the virtual machine. Marathon s everrunft will use either physical port when Windows in the virtual does I/O to the one Ethernet port it thinks it has. Motherboards are fully synchronized to look like a single motherboard, thus providing the ability to keep running the software when one motherboard drops out. Numerous configurations can be applied to create the CoServers and they are outlined in the Marathon Technologies everrunft Configuration and Installation Guide. For example, with proper network infrastructure, you could place one CoServer in one plant and place the other CoServer in a separate plant in a different geographic location. This configuration not only provides a fault-tolerant FactoryTalk AssetCentre system in a single plant but can provide failover in the event that an entire plant enters a down state. Figure 2 outlines a more detailed overview of the relationship between the CoServers, virtual server, and a typical plant network. As you can see in this figure, each CoServer is connected to a management network, the production network, and a CoServer Link. There are several items to note regarding the network design with Marathon Technologies everrunft. The management network is used exclusively to manage each of the individual CoServers. The management link can be a segmented part of your network, as shown in the above figure, or directly connected 3 P age
ASSET MANAGEMENT to your production network. The everrunft software on the CoServer uses the management link to provide management control from a management station running the Marathon everrunft Manager. The management link is not visible to the virtual machine. The redirected link is the Ethernet port seen by the virtual server, and represented by a pair of physical connections (one on each CoServer) to the production network and thus redirected from each CoServer to the virtual server. The redirection provides the virtual server hosting the FactoryTalk AssetCentre server with access to the network devices that it will be managing. The CoServer links are simply cross-over cables that interconnect the two CoServers to maintain the handshake between the systems. They are used by the everrunft software and not visible to the Windows software in the virtual machine. A couple of points to note with the network design outlined in Figure 2 are: Multiple network links for CoServer Links, Management Links, and Redirected Links are outlined in great detail in the Marathon Technologies everrunft Installation and Configuration Guide and Getting Started Guide. The basic idea is that anywhere you have a second connection, it is a fault-tolerant connection. Therefore, if you have two CoServer links, as in Figure 2, if CoServer link 1 fails, then the system automatically fails over to the CoServer link 2. The Management Network shown in the figure on the previous page is segmented from the production network. The design trade-off here is that the CoServers have no direct visibility on the production network, thus preventing users from attempting to access them remotely over the production network. Rockwell Automation has completed the FactoryTalk AssetCentre testing on Marathon Technologies everrunft. Based on the results of this qualification, Rockwell Automation supports FactoryTalk AssetCentre deployments on Marathon Technologies everrunft. The installation details and procedures found in the next section outline the process used by Rockwell Automation to deploy FactoryTalk AssetCentre on Marathon Technologies everrunft platform. Installation Procedure Software Version Qualified Products and versions tested on the Marathon Technologies everrunft platform: Operating System: Microsoft Windows Server 2003 R2 Enterprise Edition Version: 5.2.3790 Latest Patch Date: Installed all critical Microsoft patched as of 7/18/2008 Marathon Version: everrun FT 7.1.1 FactoryTalk AssetCentre Version: CPR9-2.21.00.1180 4 P age
MAXIMIZING UPTIME Marathon Technologies everrunft Installation Note: The outline below is simply an overview of the steps required to install the Marathon Technologies everrunft software. Be sure to follow the installation instructions in the everrunft Installation and Configuration Guide. Make sure to check the documentation that was included with your purchase of EverRunFT prior to installing any software. Install Microsoft Windows Server 2003 on each of the CoServers. o Note that Windows Server 2003 R2 was used by Rockwell Automation to complete testing of this procedure. Install the necessary Windows service packs and security patches on each CoServer, as well as any necessary virus or company-required management software. o Prior to installing any anti-virus software or system management software such as Altiris, contact your Marathon Technologies everrunft customer support team member to verify that the software package you are installing is supported on everrunft. Configure the Marathon Technologies everrunft software on each CoServer using the instructions found in Chapter 2 of the Marathon Technologies everrunft Installation and Configuration Guide. o Be sure to configure a large enough virtual disk drive for the Marathon virtual machine. The default is 4GB for the Marathon Virtual Disk. Be sure to build a virtual disk that is large enough to host the Microsoft SQL Server database that FactoryTalk AssetCentre will use for storage. Rockwell Automation recommends at least a 20GB virtual disk drive. Install Microsoft Windows Server 2003 on each of the virtual machine. o Note that Windows Server 2003 R2 was used by Rockwell Automation to complete testing of this procedure. Configure your newly built virtual server on the domain or workgroup on which you will be using FactoryTalk AssetCentre. 5 P age
ASSET MANAGEMENT The figure to the left shows a successful configuration of Marathon Technologies everrunft. Note that your implementation may vary based on your design choices, but the basic layout will be the same. The figure to the left illustrates a fully functional everrunft environment consisting of two CoServers and a virtual server. In the figure to the right, notice that the virtual server status window provides the name of the virtual server, in this case FTAC-Virt_CPR9, and the status of the virtual server on each CoServer. The status and computer name of each CoServer and the status of the CoServer link between the CoServers are shown. The status of each device redirected to the virtual Server is reported. Figure 3 illustrates a system in which a disk drive, network controller, keyboard, and mouse have been redirected to the virtual server from each CoServer. Also a CD-ROM drive has been redirected from CoServer 1 but not from CoServer 2. Finally, note a warning about the status of the SplitSite service. More information is available about the SplitSite service in the Marathon Technologies everrunft Getting Results Guide. The above figure illustrates the device redirector and the specific device configuration used to complete FactoryTalk AssetCentre qualification deployed on Marathon Technologies everrunft. The device redirector shows all the devices on each of the three systems that create the everrunft system, similar to the Windows Device Manager. An important thing to note is that devices redirected to the virtual server from either of the CoServers are only visible under the virtual server, not under the individual CoServer even though the physical device resides on the CoServer. At this point, you have successfully set up and configured Marathon Technologies everrunft software and are ready to install the FactoryTalk AssetCentre system on the virtual server. 6 P age
MAXIMIZING UPTIME Activating FactoryTalk AssetCentre In the following section of this document, you will read a step that asks you to configure FactoryTalk AssetCentre. We are putting this section first so that you are certain to see these important steps prior to beginning the FactoryTalk AssetCentre installation. After installing the FactoryTalk AssetCentre system, when you are ready to activate the FactoryTalk AssetCentre system you must be sure to use the Host ID that matches the Marathon Ethernet Redirector MAC address when downloading activations from Rockwell Software as shown in the figure below. The FactoryTalk Activation wizard will list several Host IDs that correspond to the MAC addresses of the Ethernet NIC cards used in the Marathon Technologies everrunft solution. Important: Be sure to chose a Host ID for the physical network interface that serves as the Marathon Ethernet redirected adaptor or port, NOT the Marathon virtual network adaptor or port. Activations locked to the Host ID of virtual network adaptors may fail unexpectedly. 7 P age
ASSET MANAGEMENT Be sure to read your FactoryTalk AssetCentre documentation prior to installing the software. FactoryTalk AssetCentre Server Installation Note: The outline below is simply an overview of the steps required to install the FactoryTalk AssetCentre server software. Be sure to follow the installation instructions in the FactoryTalk AssetCentre Installation Guide. Important: Installation of FactoryTalk products must be done at the everrunft Virtual Desktop Manager, using the mouse, keyboard, and display connected to the everrun FT system. The installation cannot be completed via a Window Remote Desktop connection to the virtual server. 1. Enable Microsoft Remote Desktop on the virtual server. Right-click My Computer and select Properties. In the properties window, select the Remote tab. In the Remote Desktop section of the Remote tab, select Enable Remote Desktop on this computer. You may see the warning, illustrated in the figure to the left, alerting you that some of the user accounts on this machine do not have passwords set. Accounts that these would apply to would be a system account that is not interactively available and therefore this warning can generally be ignored. If you are concerned that this could be a potential security risk to your organization, consult your IT group to get clarification for your specific organization. Click Select Remote Users to grant users privileges to connect to this computer via Windows Remote Desktop. Add the users that need to access this system remotely. You can specify either domain or local usernames. Remember that granting users access to this Remote User group does not give them any administrative rights on the system, just access to log on remotely. Members of the administrator's group on the system automatically have access to log on remotely. 8 P age
MAXIMIZING UPTIME 2. Begin the FactoryTalk AssetCentre Server installation according to the instructions found in the FactoryTalk AssetCentre Installation Guide. Important: Be sure to use the Virtual Desktop Manager directly through one of the CoServers to complete the installation: the installation will fail if you install FactoryTalk products through Windows Remote Desktop. 3. Install and configure IIS on the virtual server. 4. Install and configure Microsoft SQL Server 2005 (SP1 and later) or 2000 (SP4 and later) on the virtual server. Microsoft SQL Server can be installed on the virtual server and is completely supported by Marathon Technologies. The tradeoff here is that as your FactoryTalk AssetCentre database grows, you will fill hard drive space on the virtual disk. Therefore, you must either allocate enough hard drive space on the virtual machine or install Microsoft SQL Server on a separate machine per the instructions in the FactoryTalk AssetCentre Installation Guide. 5. Install any necessary Microsoft SQL Server Service Packs on the virtual server, or the computer on which you deployed Microsoft SQL Server. 6. Install and configure FactoryTalk Activation Server on the virtual server according to the above section entitled "Activating FactoryTalk AssetCentre Server." 7. Install FactoryTalk AssetCentre Server on the virtual server. 8. Optionally, install FactoryTalk AssetCentre Client on the virtual server. A FactoryTalk AssetCentre system requires at least one FactoryTalk AssetCentre Client. 9. Optionally, install FactoryTalk AssetCentre Agent on the virtual server. The FactoryTalk AssetCentre system supports multiple FactoryTalk AssetCentre Agents. The FactoryTalk AssetCentre Agent does not need to be installed on the FactoryTalk AssetCentre Server computer. At this point, you have successfully installed Microsoft IIS, Microsoft SQL Server, and the FactoryTalk AssetCentre system. Congratulations! You have successfully installed, configured, and activated a highavailability fault-tolerant FactoryTalk AssetCentre system deployed on a Marathon Technologies everrunft solution. 9 P age
ASSET MANAGEMENT Final Notes To ensure reliable functioning of your newly configured FactoryTalk AssetCentre system: During your regularly scheduled maintenance for FactoryTalk AssetCentre, perform a full system backup of the virtual disk drive. Do this exactly the same way you would on a standard Windows server if you use standard system backup or imaging software that can take an image while Windows is still running. For example, a disk image can be taken with ACRONIS by shutting down FactoryTalk AssetCentre (including SQL Server) and taking an image of the disk on the virtual machine. Disk imaging products that require the Windows system to be shut down require shutdown of your virtual machine and taking an image from one of the CoServers make a copy of the virtual disk drive. Maintain your Microsoft SQL Server database according to Microsoft s best practices for reliable database operation. Carefully consider your network design when configuring the network support for your Marathon Technologies everrunft system. Consider all the design tradeoffs for each configuration detailed in the Marathon Technologies everrunft Installation and Configuration Guide. 10 P age
MAXIMIZING UPTIME References Marathon Technologies Support Documentation for everrunft Release 7.1.1 o everrunft Administrator s Guide (AdminFT.pdf) o everrunft Commands (commands.pdf) o everrunft Configuration and Installation Guide (Install.pdf) o everrunft Messages (Messages.pdf) o Upgrading to everrunft Software (Upgrade.pdf) o Release Notes (ReleaseNotesFT.rtf) o Getting Started with everrunft (GettingStartedFT.pdf) Rockwell Automation Support Documentation for FactoryTalk AssetCentre CPR9-2.21.00.1180 o FactoryTalk AssetCentre Installation Guide (FTAC-IN002B-EN-E) o See http://literature.rockwellautomation.com and select Software Asset Management for these support documents. FactoryTalk Batch on Marathon Technologies everrunft Author: Lloyd Larsen, Applications Engineer Rockwell Automation FactoryTalk and Rockwell Automation are trademarks of Rockwell Automation, Inc. All other trademarks are the property of their respective companies. Publication: FTAC-WP001A-EN-E August 2008 Copyright 2008 Rockwell Automation, Inc. All Rights Reserved.