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Publication 1756-UM523F-EN-P - December 2006

Chapter

1

ControlLogix Redundancy System Overview

Introduction

This chapter provides an overview of the ControlLogix redundancy
system, including commonly used terms. It also answers some
common questions about a ControlLogix redundancy system.

Topic

Page

About the Main Parts of a Redundant System

14

Firmware Combinations That Make Up a Redundant System

14

Primary Chassis

15

Switching from One Controller to Another

15

Network Access Port

16

Bump in Outputs During a Switchover

16

Keep the Second Controller Up to Date

16

Making Online Edits

18

Increasing Scan Time

18

Network Addresses During a Switchover

18

Quick Start Checklists

21

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Summary of Contents for 1756-CNB/E

Page 1: ...ndancy System Catalog Numbers 1756 CNB D E 1756 CNBR D E 1756 ENBT 1756 EWEB 1756 L55 1756 L55M12 1756 L55M13 1756 L55M14 1756 L55M16 1756 L55M22 1756 L55M23 1756 L55M24 1756 L61 1756 L62 1756 L63 175...

Page 2: ...ation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockw...

Page 3: ...tion The document contains these changes Topic Page Series E information for 1756 CNB and CNBR modules Throughout manual Redundant System Firmware Combinations 14 Revised Procedure for Setting the Min...

Page 4: ...Publication 1756 UM523F EN P December 2006 Summary of Changes 4 Notes...

Page 5: ...g a Switchover 18 ControlNet Network 19 EtherNet IP Network 20 Quick Start Checklists 21 Chapter 2 Design the System Introduction 27 Laying Out the System 28 Placement of a Pair of Redundant Chassis 3...

Page 6: ...57 Test a Switchover 59 Before You Begin 59 Actions 59 Change Auto Synchronization 61 Actions 61 Change Program Control 62 Before You Begin 62 Actions 63 Chapter 5 Configure and Program the Controlle...

Page 7: ...a ControlNet Network 97 Schedule a New Network 97 Update the Schedule of an Existing Network 98 Check the Keepers 99 Save the Project for Each Controller 99 Set Task Watchdog Times 100 Chapter 6 Maint...

Page 8: ...ubnets Introduction 147 Keep an HMI Communicating with the Primary Chassis 148 Install the ControlLogix Redundancy Alias Topic Switcher Software 149 Configure a Driver to Communicate with the Primary...

Page 9: ...ntrolNet Bridge Modules Introduction 173 Losing Communication while Bridging Via a Series B ControlNet Bridge Module 173 Communication Stoppage While Using a Series B ControlNet Bridge Module 174 Appe...

Page 10: ...Publication 1756 UM523F EN P December 2006 10 Table of Contents...

Page 11: ...e engineers Control engineers Application engineers Instrumentation technicians When to Use This Manual Use this manual throughout the lifecycle of a redundancy system The lifecycle consists of these...

Page 12: ...et Bridge Module Series E Release Notes 1756 RN627 1756 ENBT A 1756 10 100Mbps EtherNet IP Bridge Twisted Pair Media Release Notes 1756 RN602 1756 ENBT 1756 ENBT ControlLogix EtherNet IP Product Profi...

Page 13: ...estions about a ControlLogix redundancy system Topic Page About the Main Parts of a Redundant System 14 Firmware Combinations That Make Up a Redundant System 14 Primary Chassis 15 Switching from One C...

Page 14: ...that Controls a Machine or Process At Least 2 Other ControlNet Nodes with Node Numbers That are Lower Than Those of the Two 1756 CNB Modules in the Redundant Chassis Network 2 ControlNet Network for...

Page 15: ...any of these situations in the primary chassis loss of power major fault of the controller removal insertion or failure of any module in the primary chassis break or disconnection of a ControlNet tap...

Page 16: ...switchover time is approximately 80 220 ms Keep the Second Controller Up to Date To take over control the secondary controller requires the same project as the primary controller It also requires up t...

Page 17: ...es force values online edits or any other information about the project A crossload happens initially when the chassis synchronize and then repeatedly as the primary controller executes its logic Sync...

Page 18: ...and goes back to the original code You have the option to keep the edits active after a switchover at the risk of faulting both controllers Increasing Scan Time At the end of each program the primary...

Page 19: ...s in the primary chassis use the node number to which they are set 4 2 3 5 6 7 0 1 4 2 3 5 6 7 0 1 CNB modules in the secondary chassis use the node number to which they are set plus 1 Primary Chassis...

Page 20: ...it is set An EtherNet IP module in the secondary chassis uses the IP address to which it is set 1 in the last address segment Port Configuration Switchover EtherNet IP Modules Primary Chassis Seconda...

Page 21: ...a a 1756 DNB module in a remote chassis Universal remote I O network via a 1756 DHRIO module in a remote chassis 28 31 ControlNet Network Update Times NUTs 90 ms NUTs specified relationship to each ot...

Page 22: ...RM module 1 in each redundant chassis Needs 2 slots Needs 1757 SRCx cable 1 m 3 ft 3 m 9 ft 10 m 30 ft 50 m 150 ft and 100 m 300 ft 29 30 Controllers ControlLogix5555 ControlLogix5561 ControlLogix5562...

Page 23: ...odule or its box If 1756 EWEB any catalog revision Up to 2 EtherNet IP modules in each redundant chassis within these limits 29 38 Redundant Chassis Configuration Continued Parameter Criteria Page If...

Page 24: ...an time for the entire task when the secondary controller is synchronized 100 Minimizing Scan Time A few large programs instead of a lot of small programs No unused tags Arrays and user defined data t...

Page 25: ...other HMI client software that uses RSLinx 2 x software Limit the number of RSLinx servers that a controller uses to 1 ideal to 3 maximum ControlNet Network PanelView Standard terminal PanelView 1000e...

Page 26: ...Publication 1756 UM523F EN P December 2006 26 ControlLogix Redundancy System Overview Notes...

Page 27: ...ControlLogix controller Topic Page Laying Out the System 28 Placement of a Pair of Redundant Chassis 30 Placement of the I O 31 Placement of Operator Interface Terminals 32 Additional Redundant Compo...

Page 28: ...olNet network Set NUT 90 ms Set RPIs 375 ms If multiple ControlNet networks set NUTs specified values For unscheduled communication use 4 PanelView terminals per controller At least 2 nodes in additio...

Page 29: ...chassis 1757 SRM module Only 1 in each redundant chassis Uses 2 slots ControlLogix5555 ControlLogix5561 ControlLogix5562 or ControlLogix5563 controllers Same type of controller throughout the chassis...

Page 30: ...custom fiber optic cable For a custom cable follow these rules Keep total light loss through the cable less than or equal to 7dB Keep total length less than or equal to 4 km Use high quality 62 5 125...

Page 31: ...redundant controllers no bridging to I O modules on another ControlNet network DeviceNet network Universal remote I O network IO Placement HMI Yes Universal Remote I O Network I O Yes HMI Yes DeviceN...

Page 32: ...visory Edition software with RSLinx 2 x software RSView 32 software Any other HMI client software that uses RSLinx 2 x software Limit the number of RSLinx servers that a controller uses to 1 ideal to...

Page 33: ...em Redundant ControlNet Media Redundant Power Supplies Redundant ControlNet Media Redundant ControlNet media prevents a loss of communication if a trunkline or tap is severed or disconnected It uses t...

Page 34: ...n of 1756 PA75R and 1756 PB75R 1756 PSCA chassis adapter module in place of the standard power supply Two 1756 CPR cables to connect the power supplies to the 1756 PSCA adapter User supplied annunciat...

Page 35: ...etwork contains only one node other than the redundant chassis pair that node will drop its connections during a switchover This may cause the outputs of that node to change state during the switchove...

Page 36: ...at case the switchover time is approximately 60 ms Example 2 The chassis loses power and the NUT 10 ms In that case the switchover time is approximately 80 ms Example 3 You unplug the CNB from the net...

Page 37: ...Example Guideline Details If the NUT of this network is 5 ms ControlNet Network 1 Then the NUT of this network must be 21 ms or less ControlNet Network 2 If the smallest NUT on a network is ms Then t...

Page 38: ...tops over an EtherNet IP network with your controllers and HMIs during a switchover You will not be able to communicate with them for up to a minute The actual delay depends on your network topology I...

Page 39: ...P swapping give the same IP address to the primary module and its partner A Give the same IP address subnet mask and gateway address to both modules in the redundant pair B Leave the next highest IP a...

Page 40: ...work as OK does not get the carrier signal it shows Link lost LQN ORVW LQN ORVW VZLWFK SULPDU FKDVVLV VHFRQGDU FKDVVLV ZLOO GLVTXDOLI ZRQ W V QFKURQL H WKHU1HW 3 PRGXOH VKRZV LQN ORVW ZLOO VZLWFKRYHU...

Page 41: ...s combination of circumstances The event task is in a nonredundant controller An event task is not permitted in a redundant controller A redundant controller triggers the event task via a produced tag...

Page 42: ...Publication 1756 UM523F EN P December 2006 42 Design the System Notes...

Page 43: ...PORTANT Use of the Network Access Port NAP Do not connect any device to the network access port NAP of a 1756 CNB D E or 1756 CNBR D E module in a redundant chassis If you connect a device to the NAP...

Page 44: ...A72 or PB72 power supply ControlLogix Power Supplies Installation Instructions publication 1756 5 67 1756 PA75 or PB75 power supply ControlLogix Power Supplies Installation Instructions publication 17...

Page 45: ...If you are converting an existing system that contains local I O modules you still need two additional chassis In a redundant system you must place all I O modules outside the redundant chassis pair A...

Page 46: ...o node 3 Power Supply Publication 1756 PA72 ControlLogix Power Supplies Installation Instructions publication 1756 IN078B 1756 PB72 1756 PA75R ControlLogix Redundant Power Supply Installation Instruct...

Page 47: ...WEB module or modules 2 maximum if required Connect each module to an ethernet switch 6 Install the 1757 SRM module See ProcessLogix ControlLogix System Redundancy Module Installation Instructions pub...

Page 48: ...t the CNB ENBT and EWEB modules to their respective networks 3 Connect one of these fiber optic cables to the 1757 SRM modules 1757 SRC1 1757 SRC3 1757 SRC10 1757 SRC50 1757 SRC100 2 42800 L 5 5 S R M...

Page 49: ...For example if you set the rotary switches of the CNB modules in the redundant chassis to node 11 no other device should use node 12 Use a remote chassis for communication modules such as 1756 ENET 1...

Page 50: ...on ENET UM001 You will use that publication when you configure each module Configure the EtherNet IP modules in the first chassis A Turn on the power to only one of the redundant chassis For example i...

Page 51: ...r or IP address on the front of the communication module 4 Turn off the power to the chassis 5 Turn on the power to the second redundant chassis 6 Wait for the 1757 SRM module to display PRIM 7 Flash...

Page 52: ...le show SYNC Yes Stop The system is synchronized No There is a problem The system is not synchronized Go to step 3 3 Make sure that the Auto Synchronization option of the SRMs is set to Always For hel...

Page 53: ...n Tool To configure the system redundancy module open the 1757 SRM System Redundancy Module configuration tool Complete this procedure to set the SRM clock test a switchover troubleshoot a system stor...

Page 54: ...ick the backplane to see its modules 6 Right click the 1757 SRM module and select Module Configuration IMPORTANT Check your revision of the SRM configuration tool when you open it for the first time T...

Page 55: ...e tool that you get RSLinx Software Versions IMPORTANT Make sure that you check the revision of your SRM configuration tool before you use it Later revisions of the SRM configuration tool are not comp...

Page 56: ...cy systems You will cause the 1757 SRM module to fault if you use revision 2 6 of the tool with an revision 11 x or earlier redundancy systems Keep in mind that some features are available only in rev...

Page 57: ...in its event log The secondary SRM event log records when the secondary SRM powered up Look for WCT time change 1 second event An SRM with a firmware revision 3 37 or earlier does not log its power do...

Page 58: ...Redundancy Module 2 Set the clock A Click Configuration Action Details B Do you want to set the clock of the SRM to the clock of your computer C Choose OK If Then Yes Choose Apply Workstation Time an...

Page 59: ...ogress after a switchover Typically the modules show this sequence Actions PwNS PwDS PwQg PwQS primary with no secondary primary with disqualified secondary primary with synchronizing qualifying secon...

Page 60: ...s to continue 3 Monitor the synchronization progress A Click Synchronization Status If the controller contains a large project the system may spend some time synchronizing the secondary controller B I...

Page 61: ...2 Open the SRM configuration tool for the primary chassis A Start RSLinx software B From the Communications menu choose RSWho C Open the branches of your network until you find the 1757 SRM module in...

Page 62: ...oller from doing so Perform this procedure when you initially configure the SRM decide to send the SRM a message from the controller Before You Begin See page 91 for a list of messages that a controll...

Page 63: ...choose RSWho C Open all the network branches to find the 1757 SRM module in the primary chassis D Right click the SRM and choose Module Configuration 2 Set the program control option A Click Configura...

Page 64: ...Publication 1756 UM523F EN P December 2006 64 Configure the System Redundancy Module Notes...

Page 65: ...Create and maintain only one RSLogix 5000 project for the pair of redundant controllers When you download the project to the primary controller the project automatically crossloads to the secondary c...

Page 66: ...er they will likely also fault the secondary controller To prevent faulting any test edits are deactivated untested during a switchover As an option you can keep the edits active after a switchover Re...

Page 67: ...mary controller cannot untest the edits Decide How You Want to Set Aside Unused Memory When the secondary controller receives crossload data it first buffers tag data in a quarantine section of memory...

Page 68: ...ine toolbar click the controller button Does General display the controller type If no go to step 3 If yes go to step 6 3 Click the Change Type button 4 Select your controller 5 Click OK 6 Select Redu...

Page 69: ...events an incorrect online edit from faulting both the primary and secondary controller If you want any test edits to remain active during a switchover then check this box However by doing so you run...

Page 70: ...ntroller select a comm format of None for the remote CNB module the CNB that is physically in the redundant chassis IMPORTANT For each module in your system make sure that the requested packet interva...

Page 71: ...g Configuration C N B L 5 5 M C N B S R M Redundant Chassis To the controller with the consumed tag this is the remote CNB module Remote Chassis L 5 5 M x In the I O configuration of this controller s...

Page 72: ...ge to the Redundant Controller If the MSG instruction originates from a redundant controller Then During a switchover The message instructions status bits are updated asynchronously to the program sca...

Page 73: ...sage instruction to pause for 7 5 seconds because the initiating controller has not received a response from the targeted controller For cached messages the message instruction tries to execute three...

Page 74: ...ength of time for the crossload depends on the how much data the primary controller has to crossload The primary controller crossloads any tag to which an instruction wrote a value even the same value...

Page 75: ...crossload Size of the last crossload if you had a secondary chassis LastDataTransfer Size DINT This attribute gives the size of data that was or would have been crossloaded in the last scan The size...

Page 76: ...ams The controller stops at the end of every program to crossload data So the more programs that you have the more the controller stops to crossload And it often ends up crossloading the same data man...

Page 77: ...ytes 32 bits of memory The controller does this even if the tag needs only 1 bit When you create an array or a user defined data type the controller packs smaller data types into 4 byte 32 bit words T...

Page 78: ...base array 5 Keep user defined data types as compact as possible Put like data types together when you lay out a user defined data type Put all the BOOLs together Put all the SINTs together Put all t...

Page 79: ...itions many times Each instruction adds scan time to your controller Action Details This is better This rung checks Bool_B and Bool_C only once each scan Than this This rung checks Bool_B and Bool_C t...

Page 80: ...te the same value that was previously in the tag If you execute an instruction only when you need to you reduce the amount of crossload data This reduces scan time To limit the execution of an instruc...

Page 81: ...efficient as possible use the DINT data type instead of the SINT or INT data types A ControlLogix controller usually works with 32 bit values DINTs or REALs If you use a SINT or INT value the control...

Page 82: ...data is sent to the secondary controller Data from the program in the higher priority task Data from the first part of the program in the lower priority task B Execution returns to the program in the...

Page 83: ...data from the last update In this example the secondary controller starts the scan with an image of the data as it was during the primary controller s last scan To prevent a scan from repeating after...

Page 84: ...instructions the partially shifted array values are sent to the secondary controller If a switchover occurs before the instruction completes its execution data remains only partially shifted The secon...

Page 85: ...tion misses the last value of scan_count ACC Take Preventative Actions If logic seems susceptible to an upset during a switchover either place susceptible logic in the highest priority task or if the...

Page 86: ...endent logic Buffer Critical Data This example shows the use of a buffer together with a BSL instruction 1 The COP instruction moves the data into a buffer array 2 The BSL instruction uses the data in...

Page 87: ...oot a system Actions Use a Get System Value GSV instruction to read the attributes of the REDUNDANCY object See Appendix C for a list of attributes Example 1 Ladder Diagram Example 2 Structured Text G...

Page 88: ...not show all the attributes but it shows the more common attributes Additional Resources For more information consult these sources Appendix C Logix5000 Controllers General Instructions Reference Manu...

Page 89: ...Diagram Get the ID of the primary chassis That is always the chassis that runs the code Store the ID in the Chassis_ID_Now tag Chassis_ID_Now DINT If this is the first scan then Set the last value of...

Page 90: ...last value of the chassis ID the ID of this chassis Chassis_ID_Last DINT If S FS then Chassis_ID_Last Chassis_ID_Now End_If If the chassis ID changes a switchover happened If a switchover happens then...

Page 91: ...ecute the instructions that you want to execute after a switchover Turn off the Switchover_Happened bit If Switchover_Happened then Put your statements here Switchover_Happened 0 End_If Send a Message...

Page 92: ...ember 2006 92 Configure and Program the Controller Before You Begin Before sending a message to an SRM make sure that the SRM is configured for program control the message is unconnected Leave the Con...

Page 93: ...1 slot_number where slot_number is the left hand slot number of the 1757 SRM module Connected check box Leave the Connected check box clear unchecked You can send only unconnected messages to a 1757 S...

Page 94: ...u can send only unconnected messages to a 1757 SRM module Set the clock of the SRM module Configuration Message Type CIP Generic Service Code 10 Class name 8b Instance name 1 Attribute name 1 Source W...

Page 95: ...1 Open or create the RSLogix 5000 project for the controller 2 From the File menu choose Save 3 From the Communications menu choose Who Active Before proceeding to download your project do not try to...

Page 96: ...our controller s serial number If you then switch over to a controller in a different chassis your project will not match the new controller s serial number disabling the controller functions original...

Page 97: ...led check box 7 From the Network menu choose Properties 8 From Network Parameters type or select these parameters 9 Choose OK IMPORTANT Before you schedule a ControlNet network turn on the power to bo...

Page 98: ...ower to each chassis 2 Start RSNetworx for ControlNet software 3 From the File menu choose Open 4 Select the file for the network and choose Open 5 From the Network menu choose Online 6 Select the Edi...

Page 99: ...rks 1 Make sure the network shows all keeper capable nodes 2 Make sure that each node is a valid keeper For more information see Update a Keeper Signature on page 107 Save the Project for Each Control...

Page 100: ...er is not reset A major fault happens type 6 code 1 if the watchdog timer has too little time to completely rescan the program Action Details 1 Set the minimum watchdog time for a task Use this formul...

Page 101: ...2 maximum_scan_time 150 ms B Is your watchdog time more than the smallest watchdog time from step 4A above Yes Stop Your watchdog time is OK No Repeat step 2 and enter a new watchdog time Action Deta...

Page 102: ...Publication 1756 UM523F EN P December 2006 102 Configure and Program the Controller Notes...

Page 103: ...s stops communicating on the network For example when pair 2 powers up at 10 10 10 10 pair 1 stops communicating on the network If you want to Then see this section Page Find the cause of an unplanned...

Page 104: ...e 123 Store a project to the nonvolatile memory of a controller in a redundant system Load a project into the controller from the nonvolatile memory of the controller Store or Load a Project Using Non...

Page 105: ...oes not show NET ERR Flashing Red OK light Clear the major fault of the controller It is possible that you have to clear the fault on both the primary and secondary controllers Solid Red OK light A Cy...

Page 106: ...as compatible firmware All CNB modules in each redundant chassis are valid keepers See Update a Keeper Signature on page 107 CMPT Some module other than this CNB module does not match between the prim...

Page 107: ...ControlNet network while the secondary chassis is off or if the CNB module was previously configured in a different network Actions 1 Start RSNetWorx for ControlNet software Has this network been sche...

Page 108: ...e when a secondary chassis will not synchronize and the CNB modules in the secondary chassis show CMPT Actions If the Valid Keeper column shows Then Yes The node has a valid keeper signature No Select...

Page 109: ...ther computer is editing the project in the controller Stop the edit session The project contains test edits Untest the edits The Nonvolatile Memory Load Store dialog of the controller is open Close t...

Page 110: ...system reset it after any power loss to both chassis Actions Action Details 1 Open the SRM configuration tool for the primary chassis A Start RSLinx software B From the Communications menu choose RSW...

Page 111: ...a change of months days or hours between the log times of events Sometimes the difference is only minutes The SRM logs only significant events It does not log events while your system is running norma...

Page 112: ...to close the Extended Information Definition dialog Example 5 If the secondary log does not show the cause look at the primary log Sometimes you have to use both logs to find out what happened Example...

Page 113: ...Secondary locked for update Crossloading Error A module isn t able to get some information to its partner Disqualified Secondaries Rule A check to choose a primary chassis if both chassis power up at...

Page 114: ...Rule A check to choose a primary chassis if both chassis power up at the same time This is the final tie breaker The SRM with the lower serial number gets the first chance to become primary It becomes...

Page 115: ...able The SRM sends the message even after you remove it from the chassis This message is called a scream The scream lets the partner SRM tell the difference between a broken fiber optic interconnect c...

Page 116: ...when you knew that the chassis were in a good state export them in the CSV format which makes it easier to read and manipulate your data Action Details 1 Open the SRM configuration tool for the prima...

Page 117: ...ick the first event that you want to export from the primary chassis B Press and hold the Shift key and then click the last event that you want to export from the primary chassis C Repeat steps 3A and...

Page 118: ...ys or the chassis failed to synchronize To manually synchronize the chassis perform this procedure 1 Display RSLinx software 2 From the Communications menu choose RSWho 3 Expand the network until you...

Page 119: ...Continue waiting It may take several minutes to synchronize the secondary chassis PwQS Primary with Synchronized Qualified Secondary The secondary chassis is synchronized Skip the remaining steps in...

Page 120: ...ead time slices Continuous Task and Unscheduled Communication Ratios At a system overhead time slice of 20 default unscheduled communication occurs every 4 ms of continuous task time for 1 ms If an RS...

Page 121: ...uous task time for 1 ms Enter a System Overhead Time Slice To change the system overhead time slice perform this procedure 1 Right click on your controller and select Properties 2 Select Advanced 3 Ty...

Page 122: ...tly less than the period of the lowest priority tasks This generally leaves enough time for unscheduled communication For example in this configuration of tasks The execution time of the highest prior...

Page 123: ...percent may prevent a secondary chassis from synchronizing after a switchover To reduce the CPU usage of a module take any of these actions Change the network update time NUT of the ControlNet networ...

Page 124: ...send a message to the CNB module Use RSLinx Software 1 Start RSLinx software 2 Expand a network until the CNB module appears 3 Right click the module and choose Module Statistics 4 Click Connection M...

Page 125: ...ction Kpxx xx is the state of the module s keeper function If xx is Then the module is Ai Active network keeper with either invalid keeper information or keeper signature that does not match the keepe...

Page 126: ...rce Element Tag that uses a user defined data type Source Length 6 Destination INT tag in which to store the CPU usage of the CNB module 0 99 Communication Path 1 slot_number where slot_number is the...

Page 127: ...t Do not go back online to the primary controller until you complete the rest of the steps in this procedure 6 Go online to the secondary controller and store the project 7 Return to the Module Config...

Page 128: ...chassis B Set the Auto Synchronization option to Never C Disqualify the secondary chassis 3 Store the secondary controller s project A Go online to the secondary controller B Store the project to the...

Page 129: ...BR D module s If you want to Then see this section Page Replace 1756 CNB D or 1756 CNBR D module s with series E modules Change CNB Modules from Series D to Series E While Online 129 Change the revisi...

Page 130: ...date the firmware of the CNB module 4 Remove the CNB module 5 Repeat steps 1 4 for the rest of the CNB modules 6 Go to Actions and start the procedure Do not have a nonredundant chassis with an open s...

Page 131: ...C Open the branches of your network until you find the 1757 SRM module in the primary chassis D Right click the 1757 SRM module and choose Module Configuration 4 Disqualify the secondary chassis A Cli...

Page 132: ...are of each series E module E Remove the series E modules from the secondary chassis and set their addresses to match the original series D modules F Repeat steps B E for the second set of series E mo...

Page 133: ...nd open the network configuration file B Go online with the network You do not have to browse the entire network C Select Network Keeper Status D Select the node number of the secondary CNB and click...

Page 134: ...ol verify that the modules show full compatibility 9 Synchronize the secondary chassis A Click Synchronization B Click Synchronize Secondary and then Yes C Wait for the chassis to synchronize 10 Initi...

Page 135: ...nchronize the chassis A Go to the SRM configuration tool for the primary chassis B On the Configuration tab change the Auto Synchronization option to Always C Choose Apply and Yes 13 In the RSLogix 50...

Page 136: ...u will lose access to the network when you turn off power to the chassis Action Details 1 Upload and save the project Do you have an up to date copy of the project for the controller stored offline Ye...

Page 137: ...rogram Mode D Turn off power to the primary chassis E Go to the 1757 SRM properties of the secondary chassis F Choose Become Primary 6 Clear the fault of the new primary controller A In RSLogix 5000 s...

Page 138: ...cessor resources are not available to your application Term Description Controlling Outputs When outputs are being controlled they are active and reacting to input state changes being monitored by you...

Page 139: ...this term during the updating of a redundant system Synchronize Lock for Update Synchronizing Locking for Update Synchronized Locked for Update Switchover Locked Switchover IMPORTANT Use this procedur...

Page 140: ...ix 5000 software wait until you have completed and validated your update 2 Add the latest EDS files Start Programs Rockwell Software RSLinx Tools EDS Hardware Installation Tool 3 Put the keyswitches i...

Page 141: ...lick Synchronization F Click OK 6 Update the SRM module in the secondary chassis A Start the ControlFLASH firmware update tool B Update the 1757 SRM module in the secondary chassis 7 Synchronize the c...

Page 142: ...o online to the primary controller B Set the watchdog time for each task to this value or more Minimum watchdog time 2 maximum_scan_time 150 ms where Maximum_scan_time is the maximum scan time for the...

Page 143: ...ge the Revision of each local communication module to match what its revision will be after you update its firmware Example Suppose you plan to update the firmware of each CNB D module in the redundan...

Page 144: ...the controller in the secondary chassis The secondary chassis has the higher network address of the redundant pair B Go offline Important Stay offline until you finish this procedure 13 Lock the syste...

Page 145: ...ssis Use the ControlFLASH firmware update tool to update the rest of the modules in the new secondary chassis You have already updated the SRM module in this chassis 16 Synchronize the chassis A Go to...

Page 146: ...Publication 1756 UM523F EN P December 2006 146 Update Modules and Redundant Systems Notes...

Page 147: ...EtherNet IP subnets they keep their IP addresses during a switchover This means that your and other controllers must be able to switch between the IP address of each redundant chassis Topic Page Keep...

Page 148: ...5 Chassis A E N B L 5 5 Chassis B Topic for Chassis A Topic for Chassis B Alias Topic 012345 Xxxx Xx RSLinx Software HMI tags In your HMI project each tag references an alias topic in RSLinx software...

Page 149: ...Install the ControlLogix Redundancy Alias Topic Switcher Software The ControlLogix Redundancy Alias Topic Switcher software maintains communication between your HMI project and the primary controller...

Page 150: ...nicate with the Primary and Secondary EtherNet IP Modules 1 Start RSLinx software Modules in the redundant chassis 2 Click 3 Select Ethernet devices and choose 4 Accept the default name 5 Type the IP...

Page 151: ...1 Create a DDE OPC Topic for Each Controller 1 Browse to the controller in Chassis A 2 Right click the controller and choose Configure New DDE OPC Topic 3 Rename the topic to indicate that this is Cha...

Page 152: ...as topic that will communicate with this pair of redundant controllers 3 Add the topic for each redundant controller to the Aliased Topics list To add a topic select the topic and choose 4 Check the S...

Page 153: ...sion of RSLinx which supports OPC this error occurs 0x80040112 The text for the message depends on your operating system 1 In the tool tray right click the Redundancy Switch icon and choose Open Alias...

Page 154: ...redundant chassis has to point to the new primary chassis after a switchover Sending Message to Primary Chassis In this procedure use CIP Generic messages to determine which chassis is primary Then se...

Page 155: ...ontroller Create a Periodic Trigger for the Messages E N B L x E N B L 5 5 Chassis B MSG Type CIP Generic MSG Type CIP Generic E N B T L 5 5 M Chassis A Free running timer that triggers the execution...

Page 156: ...ssis A from the ENBT module in Chassis A Store the value in ChasA_RedundancyState data type DINT Tag Name Description Alias For Data Type Timer_RedundancyMSGs Periodic trigger for the execution of MSG...

Page 157: ...Value If Timer_RedundancyMSGs DN 1 2 seconds are up so execute the MSG instruction again And ChasB_GetRedundState_FromENBT EN 0 The MSG instruction is not currently enabled Then Execute a MSG instruct...

Page 158: ...ice Code e Class c0 Instance 1 Attribute 4 Source Element Source Length Destination ChasB_RedundancyState Path communication tab Specify the 1756 ENBT module in Chassis B Use either of these methods A...

Page 159: ...3 or 4 then ChasA_IsPrimary 1 Chassis A is the primary chassis If ChasB_RedundancyState 2 3 or 4 then ChasB_IsPrimary 1 Chassis B is the primary chassis Tag Name Description Alias For Data Type ChasA_...

Page 160: ...1 BOOL IsPrimary Each bit represents the primary status for an individual chassis within a redundant chassis pair 1 primary 0 not primary A single DINT tag for all the chassis uses less memory than a...

Page 161: ...n for the controller in Chassis B Tag Name Description Alias For Data Type ChasA_IsPrimary If set 1 then Chassis A is the primary chassis IsPrimary 0 BOOL ChasA_MSG Message instruction that transfers...

Page 162: ...Publication 1756 UM523F EN P December 2006 162 Set Up EtherNet IP Communication Across Subnets Notes...

Page 163: ...n the same chassis as the controller We recommend that you move the existing 1756 L55Mxx controller from the original chassis and place it in a redundant chassis Change any event tasks to periodic tas...

Page 164: ...In the controller organizer cut these modules from the local I O configuration and paste them into the remote CNB module I O 1756 DHRIO 1756 DNB 1756 ENET or ENB 1756 MVI Replace Local I O Tags 1 Open...

Page 165: ...5 3 Type Local 4 Type the name of the CNB module that is in the remote chassis 5 Select All Routines 6 Click Find Within 7 Select Ladder Diagrams 8 Check Instruction Operands 9 Choose Replace All The...

Page 166: ...eplacing Local with chassis_c Searching through MainProgram MainRoutine Replaced Rung 0 XIC Operand 0 XIC Local 16 I Data 0 Replaced Rung 0 OTE Operand 0 OTE Local 2 O Data 0 Replaced Rung 1 XIC Opera...

Page 167: ...2006 Convert an Existing System to Redundancy 167 3 Type Local 4 Type the name of the CNB module that is in the remote chassis 5 Select All Tags 6 Click Find Within 7 Check Alias 8 Choose Replace All...

Page 168: ...Publication 1756 UM523F EN P December 2006 168 Convert an Existing System to Redundancy Notes...

Page 169: ...o secondary 16 10 Primary locked for update Redundancy state of the partner chassis PartnerChassis RedundancyState INT GSV If Then 16 8 Synchronized secondary 16 9 Disqualified secondary with primary...

Page 170: ...centage synchronization qualification is in progress 100 Synchronization qualification is complete Keyswitch settings of the controller and its partner match or do not match KeyswitchAlarm DINT GSV If...

Page 171: ...to program 16 6 Test to program 16 7 Program to run 16 8 Test to run 16 9 Run to test 16 A Program to test 16 B Into faulted 16 C Faulted to program In a pair of redundant chassis identification of a...

Page 172: ...INTs that was crossloaded in the last scan No This gives number of DINTs that would have been crossloaded in the last scan Size of the biggest crossload Size of the biggest crossload if you had a seco...

Page 173: ...chassis 1756 CNB B or 1756 CNBR B module and 1756 DHRIO module that is connected to a remote I O network Communication Loss While Bridging Topic Page Losing Communication while Bridging Via a Series B...

Page 174: ...is situation use series D or series E ControlNet Bridge modules Communication Stoppage While Using a Series B ControlNet Bridge Module All communication on a ControlNet network could stop if the lowes...

Page 175: ...roject to the redundant controller You lose communication with the remote chassis and any devices to which you were bridging via the chassis such as the remote I O modules During the communication los...

Page 176: ...1756 CNB or CNBR D module is disconnected or breaks and then is replaced while power is still applied to the the 1756 CNB B or CNBR D module If a tap to a 1756 CNB B or CNBR B module becomes disconne...

Page 177: ...e any of these features in a ControlLogix redundancy system Local chassis I O 1756 DHRIO or 1756 DNB modules Event task Inhibit a task Motion control such as these modules 1756 HYD02 1756 L60M03SE 175...

Page 178: ...Publication 1756 UM523F EN P December 2006 178 Redundant System Restrictions Notes...

Page 179: ...Net IP module 50 message instruction 72 produced tag 70 SRM module 53 connect device via NAP 16 connection requirements 35 consumed tag configure 70 controller configure 68 download project 95 install...

Page 180: ...on 119 I I O placement 21 31 49 import event log 115 install rails 49 remote chassis 49 system 43 interpret SRM event log 109 IP address assign 50 what happens during a switchover 20 IP swapping overv...

Page 181: ...emote I O network design 21 restrictions redundant system 177 revision 13 updating system 138 RIO network design 21 S scan time See program scan time task scan time schedule ControlNet network 97 seco...

Page 182: ...ask number of 122 set watchdog time 100 test switchover 59 test edits finalize 67 what happens during a switchover 18 troubleshoot switchover 104 U update firmware 51 keeper signature 107 modules 129...

Page 183: ...all Usefulness How can we make this publication more useful for you Completeness all necessary information is provided 1 2 3 Can we add more information to help you procedure step illustration feature...

Page 184: ...NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 18235 CLEVELAND OH POSTAGE WILL BE PAID BY THE ADDRESSEE 1 ALLEN BRADLEY DR MAYFIELD HEIGHTS OH 44124 9705 PLEA...

Page 185: ......

Page 186: ...tp support rockwellautomation com Installation Assistance If you experience a problem with a hardware module within the first 24 hours of installation please review the information that s contained in...

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