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ControlLogix® Redundancy System User Manual

1. 2 lt 1 Se computer that is connected to the network access port of a remote node 43128 Publication 1756 UM523C EN P June 2003 1 2 Controllogix Redundancy Overview Term primary controller Redundancy requires no additional programming and is transparent to any devices connected over the ControlNet network It uses 1757 SRM modules to maintain communication between the pair of redundant chassis In a redundant system the following terms describe the relationship between the two redundant chassis Description The controller that is currently controlling the machine or process primary chassis The chassis that contains the primary controller secondary controller The controller that is standing by to take control of the machine or process secondary controller always resides in a different chassis than the primary controller secondary chassis The chassis that contains the secondary controller switchover Transfer of control from the primary controller to the secondary controller After a switchover the controller that takes control becomes the primary controller Its partner controller the controller that was previously the primary controller becomes the
2. If Then yes Go to step 2 no Download the project to the primary controller Place the primary controller in program mode program or remote program In the Module Configuration properties for one of the 1757 SRM modules set the Auto Synchronization option Conditional Disqualify the secondary chassis In the primary controller store the project For step by step procedures on how to store a project see Logix5000 Controllers Common Procedures publication 1756 PM001 Synchronize the controllers Initiate a switchover Disqualify the new secondary chassis In the new primary controller store the project Synchronize the controllers In the Module Configuration properties for one of the 1757 SRM modules set the Auto Synchronization option the desired option Load a Project User Initiated UD ei 4 Disqualify the secondary chassis Go online to the primary controller In the primary controller load the project For step by step procedures on how to load a project see Logix5000 Controllers Common Procedures publication 1756 PM001 Synchronize the controllers Load a Project On Power Up This Load Image option works the same as in a non redundant system When the controller loads a project on power up it does so before it activates the redundancy feature Load a Project On Corrupt Memory Publication 1756 UM523C EN P June 2003 This Load Image option works the same as
3. n 1756 CNB D 4 Expand the CNB module of the primary chassis 5 Expand the backplane Workstation Linx Gateways Ethernet AB_KTC x ControlNet n 1756 CNB D Backplane 1756 Ax XX 1756 module 1757 SRM 6 Right click the 1757 SRM module and choose Module Configuration Install the System 3 11 7 Set the Auto Synchronization option Always 1757 SRM REDUNDANCY MODULE a Click the Configuration tab Module Info Configuration Synchronization Synchronization Status Event Log Options b Choose Always ee Aways x SRM Serial Number Name 8 Choose OK Synchronize the Controllers 1 Turn on the chassis power to the partner secondary chassis 2 Wait for the 1757 SRM module to complete its power up cycle e The SRM module may take 1 to 3 minutes to power up e It may also take several minutes to synchronize the secondary controller 3 In the primary chassis what do the CNB modules display If Then Which means PwOS Primarywith The redundant chassis are synchronized Synchronized Qualified Go to Download the Project to the Primary Controller Secondary on page 3 12 PwDS Primary with A problem exits The redundant chassis are not Disqualified synchronized Secondary Go to Troubleshoot a Failure to
4. same catalog number series and revision e same memory size controller identical modules same size of chassis LIC redundant IN hassis b 5 B chassis M X zo ZA no other modules 1757 SRCx cable e 1 3 10 50 and 100 meter lengths Publication 1756 UM523C EN P June 2003 2 4 Design the System Place the 1 0 In a ControlLogix redundancy system place all I O in only the following locations VY same ControlNet network as the redundant controllers no bridging to I O modules on another ControlNet network Y DeviceNet network VW universal remote I O network il redundant chassis pair I L C IDIDICIE ControlNet network ee N 1 0 modules I H N NIN remote chassis B R B BIB 0 X 1 0 No E EtherNet IP network HMI Yes aT z X 1 0 No ControlNet network L HMI Yes 1 0 Yes DeviceNet network L HMI Yes 1 0 Yes universal remote I O network HMI Yes Publication 1756 UM523C EN P June 2003 Design the System 2 5 Add Additional Redundant In addition to using redundant pairs of controllers you have the Components option of adding the following redundant components to your system e Redundant ControlNet Media e Redundant Power Supplies Redundant ControlNet M
5. 5IN R N 5 B M B M X E Ci El A Network 1 Network 2 LIC S C TS 5IN R N 5 B M B M X E E feat El 7 n Publication 1756 UM523C EN P June 2003 Design the System 2 11 Estimate the Switchover The switchover time of a redundant system depends on the network update time NUT of the ControlNet network To estimate the Time switchover time use the following formulas For this type of failure Ifthe NUT is The switchover time is Example loss of power lt 6 60 ms For a NUT of 4 ms the switchover time 0r is approximately 60 ms WALL gt 7 5 NUT MAX 2 NUT 30 For a NUT of 10 ms the switchover time is approximately 80 ms CNB module cannot communicate 7 D 14 NUT MAX 2 NUT 30 50 For a NUT of 10 ms the switchover with any other node time is approximately 220 ms where NUT is the network update time of the network Publication 1756 UM523C EN P June 2003 2 12 Design the System Notes Publication 1756 UM523C EN P June 2003 Chapter J Install the System When to Use this Chapter Use this chapter to install the hardware of your ControlLogix redundancy system How to Use this Chapter To install your system complete the following tasks Task See page Q Review the Preliminary Information 3 1 Q Install the Chassis for the Controllers 3 4 Q Install Modules in the First Redundant Chassis 3 4 Q Install Modules in the Second Redundant Chassis 3
6. This equipment is sensitive to electrostatic discharge which can cause internal damage and affect normal operation Follow these guidelines when you handle this equipment e Touch a grounded object to discharge potential static e Wear an approved grounding wriststrap e Do not touch connectors or pins on component boards e Do not touch circuit components inside the equipment e If available use a static safe workstation e When not in use store the equipment in appropriate static safe packaging Publication 1756 UM523C EN P June 2003 3 4 Install the System Install the Chassis for the Controllers 1 Install the two ControlLogix chassis that will contain the controllers G e the redundant chassis _ 42798 e Place the chassis within the length of your 1757 SRCx cable e Install each chassis according to the ControlLogix Chassis Installation Instructions publication 1756 IN080 e If you are converting an existing system that contains local I O modules you still need two additional chassis A redundant system can use only remote I O 2 For each chassis install a ControlLogix power supply according to the corresponding installation instructions Install this power supply According to this publication 1788 PA72 CC Controllogix Power Supplies Installation 1756 PB72 Instructions publication 1
7. SRC10 SRC50 or SRC100 You also need the following materials The actual items depend on the design and lay out of your system Cat number as required for your 1 0 modules Notes For ControlLogix chassis redundant power supplies are available as an option e For a redundant power supply kit order catalog number 1756 PAR or 1756 PBR e Each kit contains two redundant power supplies cable and adapter ControlNet adapters as required for your chassis or DIN rail e You need an adapter for each remote chassis or rail e If you are using a redundant ControlNet network order the redundant R version of each adapter e You need at least two ControlNet nodes in addition to the CNB modules in the redundant chassis pair ControlNet tap 1786 TPS TPR TPYS or TPYR If you are using a redundant ControlNet network you need two taps for each device on your ControlNet network RG 6 coaxial 1786 RG6 or RG6F cable terminator 1786 XT You need 2 terminators for each ControlNet segment Publication 1756 UM523C EN P June 2003 A 2 Develop the Bill of Materials Y Oty Item RSLogix 5000 software RSLinx Lite software RSNetWorx for ControlNet software Cat number Publication 1756 UM523C EN P June 2003 Notes e For catalog numbers see the Controllogix Selection Guide publication 1756 SG001 e For compatible revisions of firmware and softw
8. condition 4 5 e ale J E e e e Publication 1756 UM523C EN P June 2003 message CEN gt CDN CERD 5 Enter message EN where message is the message control tag from step 3 42424 Maintain and Troubleshoot the System 5 27 Configure the Message Instruction Table 5 3 Message to a Module lf you want to initiate a switchover On this tab Configuration For this item 1 In the MSG instruction click M 2 Select a configuration for the message Type or select Message Type CIP Generic Service Code 4e Class name bf Instance name 1 Attribute name leave blank Source DINT tag with a value of 1 Num Of Elements 4 Destination leave blank Communication Path 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 SRM module disqualify the secondary controller Configuration Message Type CIP Generic Service Code Ad Class name bf Instance name 1 Attribute name leave blank Source DINT tag with a value of 1 Num Of Elements 4 Destination leave blank Communication Path 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
9. lf you want to Then prevent an incorrect online edit from Do not retain test edits default setting faulting both the primary and secondary controller keep test edits active during a switchover Retain test edits at the risk of faulting both controllers Publication 1756 UM523C EN P June 2003 gt memory for online addition of Tags Logic Configure and Program the Controller 4 3 Determine How to Reserve Memory When the secondary controller receives crossload data it first buffers tag data in a quarantine section of memory When it has all of the data and knows it is valid it moves the data into the main memory area That is why a redundant controller requires twice as much memory for tags as a non redundant controller The controller sets up the quarantine area at the time of download e The controller divides its memory into two sections tags including a quarantine area logic e The controller also divides its unused memory It reserves a specific amount for tags and the rest for logic You configure how to reserve unused memory between tags and logic You do this offline only before you download the project Advanced Redundancy Configuration r r Memory Usage Indicate whether more of the processor memory that is free after download is to be reserved for online creation of tags or logic Reserve more If you plan to Then while online create roughly the same amount
10. network update time NUT The repetitive time interval in which data is sent over an EtherNet IP or ControlNet network nonvolatile memory Memory of the controller that retains its contents while the controller is without power or a battery See load store NUT See network update time NUT primary chassis The chassis that contains the primary controller primary controller The controller that is currently controlling the machine or process produced tag A tag that a controller is making available broadcasting for use by other controllers See consumed tag rack optimization connection For digital I O modules you can select rack optimization communication A rack optimized connection consolidates connection usage between the controller and all the digital I O modules on a rack or DIN rail Rather than having individual direct connections for each I O module there is one connection for the entire rack or DIN rail See connection direct connection Glossary 3 requested packet interval RPI When communicating over a network this is the maximum amount of time between subsequent production of input data e Typically this interval is configured in microseconds e The actual production of data is constrained to the largest multiple of the network update time that is smaller than the selected RPI e Use a binary multiple of the network update time NUT The binary multipliers are 1 2 4 8 16 32 64
11. 2 If the OK LED of the SRM module remains solid red contact your Rockwell Automation representative or local distributor Publication 1756 UM523C EN P June 2003 Troubleshoot a Failure to Look here J Maintain and Troubleshoot the System 5 3 e lf the steps in this section do not correct the situation check the Synchronize IMPORTANT usage of the CNB modules See Adjust CNB Usage on page 5 11 e After you correct the situation manually synchronize the controllers See Manually Synchronize the Controllers on page 5 6 To determine if a pair of redundant chassis are synchronized look at the 1756 CNB D or CNBR D modules in the primary chassis Front panel If Then Which means Primary CNB PwQS Primary with Synchronized The redundant chassis are mer Qualified Secondary synchronized PwDS Primary with Disqualified Secondary A problem exists The redundant CE PWNS Primary with No Secondary chassis are not synchronized If the chassis fail to synchronize look at the 1756 CNB D or CNBR D modules in the secondary chassis Front panel Ifthe display Then So check the following shows Secondary CNB Cpt The CNB modules in the 1 All CNB modules in each redundant chassis are series D primary and secondary modules a chassis do not match in 2 Each
12. Choose Close The following example shows the results of replacing Local with chassis_c ETS Replacing Local with chassis_c Searching through MainProgram MainRoutine Replaced Rung 0 XIC Operand 0 XIC Local 16 1 Data 0 Replaced Rung 0 OTE Operand 0 OTE Local 2 0 Data 0 Replaced Rung 1 XIC Operand 0 XIC Local 16 1 Data 1 Replaced Rung 1 OTE Operand 0 OTE Local 2 0 Data 1 Replaced Rung 2 XIC Operand 0 XIC Local 16 1 Data 2 Replaced Rung 2 OTE Operand 0 OTE Local 2 0 Data 2 Replaced Rung 8 OTE Operand 0 OTE Local 15 0 CommandRegister Run Complete 7 occurrence s found 7 occurrence s replaced Replace any Aliases to Local 1 0 Tags Are any of your tags an alias for an I O device that was previously in a local chassis If Then Yes Go to step 1 No Skip this procedure 1 From the Logic menu choose Edit Tags Publication 1756 UM523C EN P June 2003 Convert an Existing System to Redundancy B 5 2 Press the Ctrl H keys replace Replace in Tag Collections x po Emen TANE 42815 QW Type Local A Type the name of the CNB module that is in the remote chassis n Select All Tags Choose Find Within gt gt MAlas 7 42815 7 Check Alias 8 Choose Replace All 9 Choose Close Publication 1756 UM523C EN P June 2003 B 6 Convert an Existing System to Redundancy Notes Publi
13. If you plan to monitor tags directly in the secondary controller not typical monitor from no more than 3 devices through a CNB module You can monitor tags in a secondary controller only via e RSLogix 5000 software e Any method that does not try to create OPC optimized packets Only a primary controller can create an OPC optimized packet Publication 1756 UM523C EN P June 2003 Configure and Program the Controller 4 9 Estimate the Scan Time of a Atthe end of each program the primary controller crossloads fresh Program data to the secondary controller as described in Chapter 1 This keeps the secondary up to date and ready to take over control but also increases the scan time when compared to a non redundant system lt scan time of program gt execute program in crossload results to primary controller secondary controller start of program end of program The length of time for the crossload depends on the amount of data that has to be crossloaded Crossloading also requires a small amount of overhead time to tell the secondary controller which program the primary controller is executing The primary controller crossloads any tag to which an instruction wrote a value even the same value since the last crossload To estimate the time for the crossload use the following formula Crossload time 0 002 to 0 003 ms DINTs 0 3 to 0 5 ms of overhead where DINTs is the amount of tag
14. Publication 1756 UM523C EN P June 2003 Maintain and Troubleshoot the System 5 9 If you increase the system overhead time slice to 33 unscheduled communication occurs every 2 ms of continuous task time for 1 ms mes i i i i BB BI 2ms 2ms 2ms 2ms 2ms 2ms 2ms 2ms 2ms continuous task E E E EHE 5 a zx mu mu i Enter a System Overhead Time Slice To change the system overhead time slice Offline j D RUN n No Forces b M Ok M BAT NoEdits A p 1 0 1 Redundancy 59 p 1 On the Online toolbar click controller properties button 2 Click the Advanced tab 2 General Serial Port System Prolfcol User Protocol Major Faults Minor Faults Date Time Advanced SFC Execution File Memory Used Unused Total Controller Fault Handler lt none gt Power Up Handler lt none gt x 3 System Overhead wie Time Slice i 3 Type or select a value for the system overhead time slice 4 Choose Publication 1756 UM523C EN P June 2003 5 10 Maintain and Troubleshoot the System Make All Your Tasks Periodic If the controller contains only a periodic task or tasks the system overhead time slice value has no effect Unscheduled communication occurs whenever a periodic task is not running For example if your task takes 50 ms to execute and you configure its update rate to 80 ms the controller has 30 ms out of every 80 ms for unscheduled communication 50 ms
15. Use this chapter to design a redundancy system for a ControlLogix controller How to Use this Chapter To design your system complete the following tasks Task See page Lay Out the System 2 2 Place the 1 0 2 4 Add Additional Redundant Components 2 5 Q Check Connection Requirements 2 6 Assign ControlNet Addresses 2 7 Q Select a Network Update Time 2 9 Q Estimate the Switchover Time 2 11 Publication 1756 UM523C EN P June 2003 2 2 Design the System Lay Out the System Figure 2 1 ControlLogix redundancy requirements and recommendations Use separate ControlNet networks for e scheduled communications 1 0 produced consumed tags e unscheduled communications HMI workstations message instructions Set NUTs lt specified values Multiple redundant chassis pairs are OK ENTIER n sk ae De Keep PanelView terminals within e these limits e lt 3 terminals per a CNB module ControlNet network Bi E e lt 4 terminals per m controller e Set NUT lt 90 ms e Set RPIs lt 375 ms lt Ne L ji r A Remote location for all SK e 1 0 e non CNB communication modules Rd d b T DIDIM To connect a computer to the ssign t
16. secondary controller Switchover Publication 1756 UM523C EN P June 2003 When a failure occurs in any of the components of the primary chassis control switches to the secondary controller A switchover occurs for any of the following reasons e any of the following situations in the primary chassis loss of power failure or major fault of the controller failure of a 1756 CNB D or CNBR D module failure of a 1757 SRM module break or disconnection of a ControlNet tap removal or insertion of a module e command from the primary controller e command from RSLinx software IMPORTANT ControlLogix Redundancy Overview 1 3 Use of the Network Access Port NAP Do not connect any device to the network access port NAP of a 1756 CNB D or CNBR D module in a redundant chassis e If you connect a device to the NAP of a CNB module in a redundant chassis a switchover will fail to occur if the CNB module is disconnected from the network While the CNB module is disconnected from the network the controller will be unable to control any I O devices through that CNB module e If you connect a workstation to the NAP of a CNB module in a redundant chassis the workstation will be unable to go online after a switchover To connect a device to a ControlNet network via a NAP use a NAP that is outside of a redundant chassis Depending on how you organize your RSLogix 5000 project outputs may or may not exper
17. 5 7 1 0 configure 4 6 Publication 1756 UM523C EN P June 2003 2 Index convert local to remote B 1 placement 1 7 2 4 3 8 redundant power supplies 2 6 import event log 5 15 initiate switchover 3 18 install system components 3 1 INT 4 10 4 11 K keeper signature check 3 16 update 5 4 L load a project from nonvolatile memory 5 30 message send to SRM module 5 24 Message instruction 4 8 Microsoft Excel import event log 5 15 MSG instruction 4 8 N NAP 1 3 3 1 network access port restrictions 1 3 3 1 network update time 2 9 nonvolatile memory load a project 5 30 store a project 5 30 NUT See ControlNet network P PanelView terminal design recommendations 2 2 periodic task 5 10 power supplies redundant 2 6 produced tag configure 4 7 program number of 4 10 program scan time 4 9 Publication 1756 UM523C EN P June 2003 minimize 4 10 overview 1 5 project create and maintain 4 1 download 3 12 load 5 30 store 5 30 0 qualify See synchronize REAL 4 11 REDUNDANCY object 5 20 remote 1 0 network design 1 7 2 4 requested packet interval 4 6 RIO network design 1 7 2 4 S scan time See program scan time task scan time schedule a ControlNet network 3 13 SINT 4 10 4 11 SRM module auto synchronization 5 18 configure 5 25 disqualify secondary 5 31 export event log 5 15 initiate switchover 3 18 install 3 5 send message to 5 24 synchronization status 3 18 synchronize contr
18. CNB module has a partner in the same slot in the other some way redundant chassis _ 3 Each pair of CNB modules one in each chassis is set to the aa same node address 4 All CNB modules in each redundant chassis are valid keepers Ol 4 See Update a Keeper Signature on page 5 4 CMPT Some module other than a 1 Each module has a partner in the same slot in the other CNB module does not redundant chassis match between the pr mary 2 Each pair of controllers one in each chassis has the same and secondary chassis memory board e g 1756 L55M14 3 Each module contains compatible firmware 4 The RSLogix 5000 project is configured for a 1756 L55 ControlLogix5555 controller and redundancy is enabled See Configure the Project for the Controllers on page 4 2 5 The Module Configuration window for the 1757 SRM module does not list any reasons for the failure to synchronize See Check the Recent Synchronization Attempts on page 5 5 DUPLNODE More than one device on 1 No other device on the ControlNet network is set to the address your ControlNet network is of the CNB modules plus one using the same node For example if the CNB modules are set to 3 no other device number should be set to 4 2 The 1757 SRCx cable is connected to both SRM modules NET ERR The ControlNet media is All ControlNet taps connectors and terminators are connected not completely connected Publication 1756 UM523C EN P June 2003 5 4 Mainta
19. Continue waiting It may take several minutes to synchronize the secondary controller PwQS Primary with Synchronized e The secondary controller is synchronized Qualified Secondary e Skip the remaining steps in this section PwDS Primary with Disqualified e The secondary controller is not Secondary synchronized e Go to step 9 9 Cycle power to the secondary chassis 10 If the CNB module in the primary chassis fails to display PwQS see Troubleshoot a Failure to Synchronize on page 5 3 If it takes too long to synchronize the secondary chassis or update your HMI there may not be enough controller time for unscheduled communication In general unscheduled communication is any type of communication that you do not configure through the I O configuration folder of the controller This type of communication Is update 1 0 data not including block transfers scheduled communication produce or consume tags communicate with programming devices unscheduled communication e g RSLogix 5000 software communicate with HMI devices execute Message MSG instructions including block transfers respond to messages from other controllers synchronize the secondary controller of a redundant system re establish and monitor 1 0 connections such as Removal and Insertion Under Power conditions this does not include normal 1 0 updates that occur during the execution of logic
20. GSV Get System Value Class name REDUNDANCY Instance name Attribute Name ModuleRedundancyState Dest redundant_state 16 0000_0000 Where Is redundant ID Tag to store the chassis label The label tells you which chassis is acting as the primary chassis e Data type is DINT e Display style is Hex redundant state Tag to store the value of the redundancy state of the controller e Data type is DINT e Display style is Hex Publication 1756 UM523C EN P June 2003 5 24 Maintain and Troubleshoot the System li Send a Message to an SRM Module Publication 1756 UM523C EN P June 2003 IMPORTANT module Leave the Connected check box clear unchecked gt Connected Send only unconnected messages to a 1757 SRM Message Configuration Msg_1 Configuration Communication Tag Path I r Wommunicaton Method f GP C DH Channel 4 LiF Witt Source Link 10 r Source ID 7 M Gechel You can use ladder logic to perform the following actions e initiate a switchover e disqualify the secondary controller e synchronize the secondary controller e set the clock of the SRM module To send a message to a module Configure the 1757 SRM Module Q Enter the Message Instruction Configure the Message Instruction Maintain and Troubleshoot the System 5 25 Configure the 1757 SRM Module To send a message to an 1757 SRM module configure the module to respond to ladder logic messag
21. If you have not already done so add the CNB module of the remote chassis to the I O configuration of the controller See the ControlLogix System User Manual publication 1756 UM001 1 0 Configuration x 1756 xxx name_ of_local_ module lt q Cut local 1 0 modules from here x 1756 CNB x name_of_local_CNB z x 1756 CNB x name_of_remote_CNB lt q Paste the 1 0 modules here 2 In the controller organizer cut the modules from the local I O configuration and paste them into the remote CNB module Cut and paste the following modules e I O e 1756 DHRIO e 1756 DNB e 1756 ENET or ENB e 1756 MVI Replace Local 1 0 Tags 1 Open a routine If a routine is already open click within the routine to activate the window Publication 1756 UM523C EN P June 2003 Convert an Existing System to Redundancy B 3 2 Press the Ctrl H keys replace Replace in Routines 42804 3 Type Local 4 Type the name of the CNB module that is in the remote chassis 5 Select All Routines 6 Choose Find Within gt gt Instruction Main Operand Comments Minstruction Operands g Instructions MiRung Comments ORung Types 42805 8 7 Select Ladder Diagram 8 Check Instruction Operands 9 Choose Replace All Publication 1756 UM523C EN P June 2003 B 4 Convert an Existing System to Redundancy The Search Results tab displays the changes to the logic 10
22. Synchronize on page 5 3 Publication 1756 UM523C EN P June 2003 3 12 Install the System Download the Project to the Primary Controller To expand a network one level do one of the following e Double click the network e Select the network and press the key e Click the sign Publication 1756 UM523C EN P June 2003 You only have to download the project to the primary controller When the secondary controller is synchronized the system automatically crossloads the project to the secondary controller TAN lf the secondary chassis becomes disqualified after you download the project make sure e the project is configured for a 1756 L55 ControlLogix5555 controller e redundancy is enabled See Configure the Project for the Controllers on page 4 2 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 F Workstation Linx Gateways Ethernet AB_KTC x ControlNet 4 Navigate to the CNB module of the primary chassis The primary chassis uses the node to which its rotary switches are set primary chassis tt D secondary chassis Jj Workstation Linx Gateways Ethernet AB_KTC x ControlNet n 1756 CNB D n 1 1756 CNB D 5 Expand the CN
23. and 128 For example if the NUT is 5 ms use an RPI of 5 10 20 40 ms etc See network update time NUT RPI See requested packet interval RPD secondary chassis The chassis that contains the secondary controller secondary controller The controller that is standing by to take control of the machine or process SMAX In a ControlNet network the maximum scheduled address The greatest node number to use scheduled communications on a ControlNet network store To copy a project to the nonvolatile memory of the controller This overwrites any project that is currently in the nonvolatile memory See load nonvolatile memory switchover Transfer of control from the primary controller to the secondary controller After a switchover the controller that takes control becomes the primary controller Its partner controller the controller that was previously the primary controller becomes the secondary controller Publication 1756 UM523C EN P June 2003 Glossary 4 synchronize The process that readies a secondary controller to take over control if a failure occurs in the primary chassis During synchronization the 1757 SRM modules checks that the partner modules in the redundant chassis pair are compatible with each other The SRM module also crossloads transfers the content of the primary controller to the secondary controller Synchronization occurs when the secondary chassis powers up It may also occur at
24. bridge communications from the serial port of the controller to other ControlLogix devices via the ControlLogix backplane Publication 1756 UM523C EN P June 2003 5 8 Maintain and Troubleshoot the System To improve the speed of unscheduled communication If your RSLogix 5000 project contains Then See page only a continuous task and no other tasks Choose a Greater System Overhead Time 5 8 This is the default task configuration Slice more than one task i e at least 1 periodic Make All Your Tasks Periodic 5 10 task Choose a Greater System Overhead Time Slice The system overhead time slice specifies the percentage of time excluding the time for periodic tasks that the controller devotes to unscheduled communication The controller performs unscheduled communication for up to 1 ms at a time and then resumes the continuous task The following table shows the ratio between the continuous task and unscheduled communication at various system overhead time slices At this time slice The continuous tasks runs for And unscheduled communication occurs for up to 10 9 ms 1ms 20 4 ms 1ms 33 2 ms 1ms 50 1 ms 1ms At a system overhead time slice of 20 default unscheduled communication occurs every 4 ms of continuous task time for 1 ms Legend EBED Task executes Task is interrupted suspended 1ms 1ms 1ms 1ms 1ms unscheduled communication H 4 ms 4 ms 4 ms 4 ms 4 ms
25. comm format of None for the remote CNB module the CNB that is physically in the redundant chassis produced tag To the controller with the consumed tag this is the remote CNB module redundant chassis v eee Lic s 5 R 5 B M M X N data consumed tag remote chassis aa x Foun re In the 1 0 configuration of this controller select a comm format of None for the remote CNB module Publication 1756 UM523C EN P June 2003 4 8 Configure and Program the Controller Configure Message MSG Instructions If the MSG instruction Then is from a redundant In a redundant controller any MSG instruction that is in progress during a switchover experiences an error controller The ER bit of the instruction turns on After the switchover normal communication resumes to a redundant controller For any MSG instruction from a controller in another chassis to a redundant controller cache the connection Properties of the Message to the Redundant Controller Message Configuration Message_1 Configuration Communication Tag Path Redundant_Controller q path to the redundant controller Redundant_Controller lommunicaion Wetod CGR DHF Chane Destination lik ri TIRE Source Link Destination Wade Source IV Cache Connections e 42977 t Leave this box checked Configure Tags for an HMI
26. in a non redundant system When the controller loads a project due to corrupt memory it does so before it activates the redundancy feature Update a Module Maintain and Troubleshoot the System 5 31 Use the following steps to upgrade the revision of your redundant modules This procedure minimizes the time your process is down for the upgrade TNT Ya Do not connect your computer to the ControlNet network via the network access port on a CNB module in the primary chassis When you turn off power to the chassis you will lose access to the network To update a module Disqualify the Secondary Chassis Q Upgrade the Required Firmware of the Secondary Chassis Make the Secondary Controller the New Primary Controller Q Upgrade the Other Redundant Chassis Change the Auto Synchronization Option to ALWAYS Disqualify the Secondary Chassis 1 Start RSLinx software 2 Find the SRM module in the secondary chassis The secondary chassis is one Workstation node greater than the primary De chassis Linx Gateways Ethernet AB_KTC x ControlNet xx 1756 CNB D xy 1756 CNB D Backplane 1756 Ax gt XX 1756 module 1757 SRM Publication 1756 UM523C EN P June 2003 5 32 Maintain and Troubleshoot the System 3 Right click the 1757 SRM module and select Module Configuration 4 Click the Configuration tab
27. of new tags Leave the default setting and new logic while online create a relatively large amount of new tags Drag to slider toward Jags but a much smaller amount of new logic while online create a relatively large amount of new logic Drag to slider toward Logic but a much smaller amount of new tags Publication 1756 UM523C EN P June 2003 4 4 Configure and Program the Controller Configure a Controller for Redundancy 1 Open or create the RSLogix 5000 project 2 On the Online toolbar click the controller button 3 Does the General tab show that the controller type is a 1756 L55 controller If Then No A Click the Change Type button B Select a 1756 L55 controller C Choose OK Yes Go to step 4 4 Click the Redundancy tab 5 Select the Redundancy Enabled check box Em me een eine 6 Click the Advanced button Publication 1756 UM523C EN P June 2003 Configure and Program the Controller 4 5 Advanced Redundancy Configuration 7 We recommend that you leave this check box cleared unchecked This prevents an incorrect online edit from faulting both the primary and secondary controller If you want any test edits to remain active during a switchover at the risk of faulting both controllers then check this check box 8 For online editing choose how you want to reserve any free memory 9 Choose ren 10 To close the Controller Properties dialog box choos
28. of whether or not it is configured for redundancy a ControlLogix controller typically compares or manipulates values as 32 bit values DINTs or REALs e The controller typically converts a SINT or INT value to a DINT or REAL value before it uses the value e If the destination is a SINT or INT tag the controller typically converts the value back to a SINT or INT value e The conversion to or from SINTs or INTs occurs automatically with no extra programming But it takes extra execution time and memory To increase the efficiency of your logic minimize the use of SINT or INT data types Publication 1756 UM523C EN P June 2003 Configure and Program the Controller 4 11 Use Arrays and User Defined Data Types To update the secondary controller the primary controller divides its memory into blocks of 256 bytes Anytime an instruction writes a value the primary controller crossloads the entire block that contained the value For example if your logic writes only 1 BOOL value to a block the controller crossloads the entire block 256 bytes To minimize scan time organize your data into arrays and user defined data types structures whenever possible Arrays and structures provide these advantages e Data is more compact This lets the primary controller crossload it more quickly e Related data is grouped together Related data is likely to change at the same time Since the controller crossloads data in 256 byte bl
29. other times system overhead time slice Specifies the percentage of time excluding the time for periodic tasks that the controller devotes to unscheduled communication Unscheduled communication includes e communicate with programming and HMI devices such as RSLogix 5000 software e respond to messages e send messages including block transfers e re establish and monitor I O connections such as RIUP conditions this does not include normal I O communications that occur during program execution e bridge communication from the serial port of the controller to other ControlLogix devices via the ControlLogix backplane e synchronize the secondary controller of a redundant system The controller performs unscheduled communication for up to 1 ms at a time The following table shows the ratio between the continuos task and unscheduled communication at various system overhead time slices At this time slice The continuous tasks runs for And unscheduled communication occurs for up to 10 9 ms 1ms 20 4ms 1 ms 33 2ms 1 ms 50 1 ms 1 ms UMAX In a ControlNet network the maximum unscheduled address The greatest node number that you will use on a ControlNet network Publication 1756 UM523C EN P June 2003 Glossary 5 watchdog Specifies how long a task can run before triggering a major fault e Each task has a watchdog timer that monitors the execution of the task e A watchdog time can range from 1 m
30. secondary controller To configure and program your controller complete the following tasks Task See page Configure the Project for the Controllers 4 2 Configure Communications 4 6 Q Estimate the Scan Time of a Program 4 9 Q Minimize Scan Time 4 10 Maintain the Integrity of Your Data During a Switchover 4 15 Set the Task Watchdog Times 4 20 Publication 1756 UM523C EN P June 2003 4 2 Configure and Program the Controller Configure the Project for To configure the project for your controller the Controllers Determine When to Retain Test Edits Determine How to Reserve Memory Configure a Controller for Redundancy Determine When to Retain Test Edits When you edit your logic while online with the controller it is possible for those edits to fault the controller and cause a switchover Tag_3 Tag_4 Tag_5 Test Edits 2 Tag_ 3 Tag 5 DD If the test edits fault the primary controller it is likely they will fault the secondary controller as well To prevent this from occurring any test edits are deactivated untested during a switchover As an option you can keep the edits active after a switchover Advanced Redundancy Configuration r Memory Usage Indicate whether more of the processor memory that is free after download is to be reserved for online creation of tags or logic Reserve more memory for online addition of Tags Logic I
31. was previously in the tag To minimize scan time execute instructions only when required if possible Use techniques such as e Make a rung false when you don t need to execute its instructions e Divide your logic into subroutines and execute each subroutine only when required This reduces the amount of crossload data which reduces scan time Publication 1756 UM523C EN P June 2003 4 14 Configure and Program the Controller EXAMPLE Execute an instruction only when required Each time the following rung executes the ADD instruction writes the sum of Tag_1 Tag_2 to Dest_Tag DD Add Source Tag_1 pe Source B Tag_2 Dest Dest Tag pe Regardless of whether the value in Dest_Tag changed from the last scan the controller marks Dest_Tag to be included in the next crossload If your application needs to recalculate Dest_Tag only when it gets new data you could modify the rung as follows New Data DD Add Source Tag_1 pe Source B Tag_2 0e Dest Dest_T ag 0e The ADD instruction now executes only when the controller gets new data New_Data on And Dest_Tag crossloads only when the ADD instruction produces a new value Publication 1756 UM523C EN P June 2003 Configure and Program the Controller 4 15 Maintain the Integrity of Your Data During a Switchover The redundancy system guarantees bumpless switchover for any logic in the highest priority task In some cases logi
32. we make things clearer all provided information is easy to understand Other Comments You can add additional comments on the back of this form Your Name Location Phone Your Title Function Would you like us to contact you regarding your comments No there is no need to contact me Yes please call me Yes please email me at Yes please contact me via Return this form to Allen Bradley Marketing Communications 1 Allen Bradley Dr Mayfield Hts OH 44124 9705 Phone 440 646 3176 Fax 440 646 3525 Email RADocumentComments ra rockwell com Publication ICCG 5 21 January 2001 PN 955107 82 Other Comments PLEASE FASTEN HERE DO NOT STAPLE PLEASE FOLD HERE BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 18235 CLEVELAND OH POSTAGE WILL BE PAID BY THE ADDRESSEE Allen Bradley BELIANCE E ELECTRIC ADN LS DOGE Rockwell Automation 1 ALLEN BRADLEY DR MAYFIELD HEIGHTS OH 44124 9705 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES PLEASE REMOVE ControlNet is a trademark of ControlNet International Ltd DeviceNet is a trademark of the Open DeviceNet Vendor Association Microsoft is a registered trademark of Microsoft Corporation in the United States and or other countries Rockwell Automation Rockwell Automation provides technical information on the web to assist you in using our products At http support rockwel
33. 0 milliseconds more than one CNB module in a redundant chassis Table 2 2 NUTs for multiple ControlNet networks If the smallest NUT on a network the CNB modules are on the same network Use a NUT that is less than or equal to 90 milliseconds the CNB modules are on different networks The NUT of each network must be within the values indicated in Table 2 2 If you use a larger NUT the controller could lose its connection with a module during a switchover This could cause outputs to change state Then the largest NUT on any other If the smallest network must be less than or equal NUT on a network Table 2 2 NUTs for multiple ControlNet networks Continued Then the largest NUT on any other network must be less than or equal is ms to ms is ms to ms 2 15 20 52 3 17 21 55 4 19 22 57 5 21 23 59 6 23 24 62 7 25 25 64 8 27 26 66 9 29 27 68 10 31 28 71 11 33 29 73 12 35 30 75 13 37 31 78 14 39 32 80 15 41 33 82 16 43 34 84 17 46 35 87 18 48 36 89 19 50 37 90 90 Publication 1756 UM523C EN P June 2003 2 10 Design the System EXAMPLE Network Update Times for Multiple ControlNet Networks If the NUT of this network is 5 ms Then the NUT of this network must be 21 ms or less T LIC S
34. 1 12 10 0 511 1994560 11 32 8 511 1894559 11 32 1 51 1894556 11 24 6 41 1994557 11 23 3 511 1994556 11 21 3 41 1894555 11 21 3 511 __Dekte 1894554 11 21 2 511 Type the number format code using one of the existing codes as a starting 1aq45na 11109 51 Pen 3 From the Category list select Custom 4 In the Type box enter the following format m d yyyy h mm ss 000 Publication 1756 UM523C EN P June 2003 5 18 Maintain and Troubleshoot the System Configure the The Auto Synchronization option determines when the 1757 SRM Auto Synchronization modules attempt to synchronize the controllers Option Choose an Auto Synchronization Option If you want the SRM modules to Then choose this Notes Auto Synchronization option always try to synchronize the controllers Always default This is the typical option e always try to synchronize the controllers until Conditional Use this option if you frequently expect to you manually disqualify the secondary chassis e once you disqualify the secondary chassis never try to synchronize the controllers until you manually synchronize the controllers manually toggle in and out of the disqualified condition With this option e When you synchronize the controllers the SRM modules try to keep the controllers synchronized e When you disqualify the secondary chassis the SRM modules no longer try to keep the controller synchronized l never try to synchronize the contro
35. 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Options 5 gt Auto Synchronization Always gt SRM Seri Name a Descriptio Chassis ID Chassis B Location IV Enable User Program Control 5 Select NEVER 6 Choose Apply and then Yes to confirm 7 Click the Synchronization tab 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log Commands Synchronize Secondary Disqualify Secondary Initiate Switchover Become imaw 8 Choose Disqualify Secondary 9 Choose Yes to confirm Upgrade the Required Firmware of the Secondary Chassis See theControlLogix Controller and Memory Board Installation Instructions publication 1756 IN101 Publication 1756 UM523C EN P June 2003 Maintain and Troubleshoot the System 5 33 Make the Secondary Controller the New Primary Controller Start RSLogix 5000 software Download the project to the secondary controller When it is safe to stop the control of your system change the primary controller to Program Mode Turn off power to the primary chassis Go to the 1757 SRM properties of the secondary chassis 1757 SRM REDUNDANCY MODULE Properties Ed gropgessesssssossseses Commands Spnenonze seconda 10 Disgualiip Secondary esogooooooo osoooooq I Ha T T SCHOE Become Primary 42808 Choose Become Pr
36. 4 Q Install the Remote Chassis or Rails 3 4 Q Flash the Modules 3 4 Q Synchronize the Controllers 3 10 Q Download the Project to the Primary Controller 3 12 Q Schedule the Networks 3 13 Test the Switchover 3 17 Preliminary Information IMPORTANT Use of the Network Access Port NAP Do not connect any device to the network access port NAP of a 1756 CNB D or CNBR D module in a redundant chassis e If you connect a device to the NAP of a CNB module in a redundant chassis a switchover will fail to occur if the CNB module is disconnected from the network While the CNB module is disconnected from the network the controller will be unable to control any I O devices through that CNB module e If you connect a workstation to the NAP of a CNB module in a redundant chassis the workstation will be unable to go online after a switchover To connect a device to a ControlNet network via a NAP use a NAP that is outside of a redundant chassis Publication 1756 UM523C EN P June 2003 3 2 Install the System Install this component 1756 A4 A7 A10 A13 or A17 chassis This chapter provides the sequence of tasks and the critical actions for the successful installation of your ControlLogix redundancy system It does not replace the installation instructions for the components of the system As you install your system refer to the following publications According to this publication ControlLogix Chassis Installation Instru
37. 50 ms 50 ms 30 ms 30 ms 30 ms If you have multiple tasks make sure that 1 The execution time of a highest priority task is significantly less than its update rate 2 The total execution time of all your tasks is significantly less than the update rate of the lowest priority tasks For example in this configuration of tasks Task Priority Execution time Rate 1 higher 20 ms 80 ms 2 lower 30 ms 100 ms total execution time 50 ms 1 The execution time of the highest priority task Task 1 is significantly less than its update rate 20 ms is less than 80 ms 2 The total execution time of all tasks is significantly less than the update rate of the lowest priority task 50 ms is less than 100 ms This generally leaves enough time for unscheduled communication Adjust the update rates of the tasks as needed to get the best trade off between executing your logic and servicing unscheduled communication Publication 1756 UM523C EN P June 2003 J Adjust CNB Usage Maintain and Troubleshoot the System 5 11 For each CNB module in a redundant chassis keep CPU usage to less than 75 percent e Each redundant CNB module needs enough additional processing time for redundancy operations e At peak operations such as synchronization redundancy uses an additional 8 percent approximately of the CPU of the CNB module e A total CPU usage that is higher than 75 percent may prevent a secondary chassis from synchroni
38. 756 5 67 1756 PA75 ControlLogix Power Supplies Installation 1756 PB75 Instructions publication 1756 5 78 Publication 1756 UM523C EN P June 2003 Install the System 3 5 Install Modules in the First Redundant Chassis Set the rotary switches of the 1756 CNB D or IMPORTANT IMPORTANT CNBR D modules for both redundant chassis to the same node address 1 Set the rotary switches of each of the 1756 CNB D or CNBR D e modules to the primary node number from Table 2 1 on page 2 8 42796 For example if you allocated nodes 3 and 4 for the redundant chassis set both CNB modules to node 3 This is only an example You can install the module in any slot n ani Semen C T N B 42798 2 Install a 1756 CNB D or CNBR D module See ControlLogix ControlNet Bridge Installation Instructions publication 1756 IN571 WARNING If you connect or disconnect the ControlNet cable with power applied to this module or any device on the network an electrical arc can occur This could cause an explosion in hazardous location installations Be sure that power is removed or the area is nonhazardous before proceeding 3 Connect the CNB module to the ControlNet network Publication 1756 UM523C EN P June 2003 3 6 Install the System 4 5 S C S 5 N R 5 B M This is only
39. AMPLE Set the clock of the 1757 SRM module When set_time is on the GSV instruction gets the current value of the WALLCLOCKTIME object and stores the value in the WallClockTime array 64 bits The message instruction then sends the value to the SRM module GSV Get System Value Class name WALLCLOCKTIME Instance name Attribute Name CurrentValue Dest WallClockTime 0 0 set time msg_set_time EN MSG Type CIP Generic Ba Message Control msg_set_time M Publication 1756 UM523C EN P June 2003 5 30 Maintain and Troubleshoot the System Store or Load a Project Using Nonvolatile Memory Term nonvolatile memory Nonvolatile memory lets you keep a copy of your project on the controller Description Memory of the controller that retains its contents while the controller is without power or a battery store To copy a project to the nonvolatile memory of the controller This overwrites any project that is currently in the nonvolatile memory load To copy a project from nonvolatile memory to the user memory RAM of the controller If you want to do this ina redundant system Store a Project This overwrites any project that is currently in the controller In a redundant system you can store or load a project only while the secondary chassis is disqualified Do this om o P moO O CO s Does the primary controller already contain the project that you want to store
40. Allen Bradley ControlLogix Redundancy System User Manual Rockwell Automation Important User Information Because of the variety of uses for the products described in this publication those responsible for the application and use of these products must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards In no event will Rockwell Automation be responsible or liable for indirect or consequential damage resulting from the use or application of these products Any illustrations charts sample programs and layout examples shown in this publication are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Rockwell Automation does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Allen Bradley publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Rockwell Automation office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of thi
41. B module of the primary chassis Schedule the Networks 6 Expand the backplane Install the System 3 13 Workstation Linx Gateways Ethernet AB_KTC x ControlNet n 1756 CNB D Backplane 1756 Ax xx 1756 L55Mxx 7 Select the controller and choose Download A confirmation box opens 8 Choose Download IMPORTANT Before you schedule a ControlNet network turn on the power to both redundant chassis If you schedule a ControlNet network while the secondary chassis is off the keeper signature of a CNB module may not match its partner and the secondary chassis will fail to synchronize Use the following procedures to schedule your network Schedule a New Network Update the Schedule of an Existing Network Check the Keepers Q Save the Project for Each Controller Schedule a New Network 1 Turn on the power to each chassis 2 Start RSNetworx for ControlNet software 3 From the File menu choose New 4 From the Network menu choose Online Publication 1756 UM523C EN P June 2003 3 14 Install the System 5 Select your ControlNet network and choose OK 6 Select the Edits Enabled check box 7 From the Network menu choose Properties 8 From the Network Parameters tab type or select the following parameters In this box Specify Network Update Time repetitive ti
42. M 3 Right click the 1757 SRM module and select Module Configuration 4 Click the Event Log tab Publication 1756 UM523C EN P June 2003 5 16 Maintain and Troubleshoot the System 1757 SRM REDUNDANCY MODULE i ioj xj Module Info Configuration Synchronization Synchronization Status Event Log Auto Update On Log Time Export Selection 6 le Description Classificati CNBR 1 Not lonely ot lonely odule Insertion i dundancy State PwNS odule Removal J 1757 SRM 20 RM Power Up Starts Stoy co 5 Select the events that you want to export as follows a Click the first event that you want to export b Press and hold Shift and click the last event that you want to export 6 Choose Export Selection Export Event Log x 8 File name Browse r File Type Text 7 J CSV Comma Separated Value Publication 1756 UM523C EN P June 2003 7 Choose CSV Comma Separated Value 8 Supply a location and file name for the export file 9 Choose Export Maintain and Troubleshoot the System 5 17 Open and Format the CSV File 1 In Microsoft Excel software open the CSV file 2 For the Log Time column display the Format Cells dialog box Number Alignment Font Border Patterr s Protection Category pe A B C Event Time Slot oh ome O 1894564 12 15 0 51 1994563 12 15 0 51 1894552 12 10 0 5 1 189455
43. These changes include online edits force values changes to properties changes to data results of logic execution e Although online edits automatically crossload to the secondary controller they become inactive if a switchover occurs before you assemble them into the project This prevents an incorrect online edit from faulting both the primary and secondary controller You have the option to keep the edits active after a switchover at the risk of faulting both controllers At the end of each program the primary controller pauses its execution to crossload the result of any output instruction that executed in the program This results in an increased program scan time for a synchronized redundancy system lt scan time of program gt execute program in crossload results to primary controller secondary controller start of program end of program Publication 1756 UM523C EN P June 2003 1 6 ControlLogix Redundancy Overview ControlNet Node Addresses Each CNB module in a redundant chassis shares a pair of ControlNet primary chassis mar 24 CNB modules in the primary chassis use the node number to which they are set secondary chassis 25 CNB modul
44. U S A
45. V KK KK KK KIRI RR KII A 1 Appendix B IRON S di ane peo XW WA K d oe O an eee ESE B 1 Convert Local Modules to Remote Modules B 1 Re Configure the Local I O Modules B 2 Replace Local ZO Tass ps5 Hi GS RS Wan l d 2 B 2 Replace any Aliases to Local I O Tags B 4 Publication 1756 UM523C EN P June 2003 Table of Contents 4 Publication 1756 UM523C EN P June 2003 Chapter 1 Introduction Basic Operation ControlNet Network 1 HMI communications identical pair of ControlLogix chassis that control your machine or process ControlLogix Redundancy Overview This chapter gives you an overview of the ControlLogix redundancy system including terms that are commonly used For information on See page Basic Operation 1 1 Switchover 1 2 Synchronization 1 4 Crossloading Tag Values 1 5 ControlNet Node Addresses 1 6 Quick Start Checklists 1 7 The ControlLogix redundancy system uses an identical pair of ControlLogix chassis to keep your machine or process running if a problem occurs with a controller The following diagram shows the layout of a simple redundant set up 0000 0000 oo jpg 90509 00000 60860 ControlNet Network 2 1 0 communications ti Il Il i i at least 2 other ControlNet nodes
46. ach other The SRM module also crossloads transfers the content of the primary controller to the secondary controller Synchronization occurs when you turn on power to the secondary chassis It may also occur at other times disqualified Publication 1756 UM523C EN P June 2003 Indicates that the secondary control has failed to synchronize with the primary controller If a secondary controller is disqualified it is unable to take over control of the machine or process You also have the option of manually disqualifying a secondary controller The 1757 SRM modules maintain communication between the primary and secondary chassis primary chassis 1757 SRM modules crossload 6 fe secondary chassis ControlLogix Redundancy Overview 1 5 Crossloading Tag Values In a pair of redundant chassis the first chassis that you turn on becomes the primary chassis When you turn on power to the secondary chassis that chassis synchronizes itself with the primary chassis e You do not download the project to the secondary controller While the secondary controller is synchronizing with the primary controller the 1757 SRM modules automatically transfer the project from the primary controller to the secondary controller e Once the secondary controller is synchronized the 1757 SRM modules keep the controller synchronized by crossloading any changes that occur in the primary controller
47. ae a a a e a Ea A a E aAA R 1 2 Syhehroni ZAU ON sy Zik a AW ey 0 PA ATEN O eA 1 4 Crossloading Tag Values he hn Ped Cag Seat es 1 5 ControlNet Node Addresses 1 6 Quick Start Checklists 44 AT eh ek dk Ras 1 7 System Lay OU Bern 4 0 Dane AMENER Ses 1 7 Redundant Chassis Configuration 1 8 RSLogix 5000 Project soana KK KK KK KK KK KK KK 1 8 Chapter 2 How to Use this Chapter KK KI KIR KIRR KII KIR 2 1 Lay Out the System kk KK dome K KIR KI KI KI KIR KI K K IK ae 2 2 Place the T O arroas G2 eo os Ne rk de i kri ee 2 4 Add Additional Redundant Components 2 5 Redundant ControlNet Media n metier 28 20 2 5 Redundant Power Supplies 2 6 Check Connection Requirements 2 6 Assign ControlNet Addresses 2 7 Select a Network Update Time dus a bea da ea we dime a 2 9 Estimate the Switchover Time Al du ders bites dtan 2 11 Chapter 3 When to Use this Chapter ni TA kK KK KIRI R KIR KII 3 1 How to Use this Chapter IK KI KIR KIR KIR KIRI KIIR 3 1 Preliminary Information ss a ES KK ve Gi KK KK 3 1 Install the Chassis for the Controllers 3 4 Install Modules in the First Redundant Chassis 3 5 Install Modules in the Second Redundant Chassis 3 7 Install the Remote Chassis or Rails 3 8 Flash the Modules a4 ess 2 w2 ee are Site 3 9 S
48. an example You can install the modules in any slot Publication 1756 UM523C EN P June 2003 42799 4 Install the 1756 L55Mxx controller See ControlLogix Controller and Memory Board Installation Instructions publication 1756 IN101 5 Install the 1757 SRM module See ProcessLogix ControlLogix System Redundancy Module Installation Instructions publication 1757 IN092 Install the System 3 7 Install Modules in the Second Redundant Chassis 1 D L J C S SR LI C S TES 5 N R 5 N R 5 B M 5 B M 42800 3 IMPORTANT e The modules in each redundant chassis must match each other slot by slot e Set the rotary switches of the 1756 CNB D or CNBR D modules for both redundant chassis to the same node address 1 For each module in the first redundant chassis install an identical module into the same slot of the second redundant chassis 2 Connect the CNB module s to the ControlNet network 3 Connect the 1757 SRC1 SRC3 SRC10 SRC50 or SRC100 fiber optic cable to the 1757 SRM modules Publication 1756 UM523C EN P June 2003 3 8 Install the System Install the Remote Chassis or Rails on waa D You must install all I O modules and additional types of communication modules i
49. are see the ControlLogix Redundancy System Release Notes publication 1756 RN582 Appendix B Convert an Existing System to Redundancy Introduction If you are adding redundancy to an existing system follow these suggestions e If you change the node number of a CNB module you may affect messages tags or listen only connections in other devices Choose node numbers that have the least impact on existing communications If your existing system contains local I O modules you still need two additional chassis A redundant system can use only I O that is in a remote chassis e not in 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 Convert Local Modules to If you are converting an existing system to a redundant system Remote Modules idee Then contained only 1 0 modules that You do not have to change the 1 0 configuration of were not in the same chassis as the controller the controller contained local 1 0 modules Use the procedures in this section to convert the configuration of local modules to remote modules To convert a local module to a remote module Q Re Configure the Local I O Modules Replace Local I O Tags Replace any Aliases to Local I O Tags Publication 1756 UM523C EN P June 2003 B 2 Convert an Existing System to Redundancy Re Configure the Local 1 0 Modules 1
50. ask to revise the watchdog time if required Set the Watchdog Time for a Task To set the watchdog time for a task Controller Primary Tasks MainTask g ___ 1 Right click the task and choose Properties 2 Click the Configuration tab Corine z m 3 Type the watchdog time med CW BTN maten ns anang JEYWETIT NT BETI E lS IR TET TET 43080 4 Choose Rav Publication 1756 UM523C EN P June 2003 4 22 Configure and Program the Controller Determine the Scan Time of a Task To get the actual scan times for a task Controller Primary Tasks MainTask amp _ 1 1 Right click the task and choose Properties 2 Click the Configuration tab T Task Properties MainT ask HETE UT BT8 Hater me Enang IGWERRUNUE Deas tigen pian maximum time that it took to execute this task in microseconds 3 To close the dialog box choose ox Publication 1756 UM523C EN P June 2003 Chapter 5 Maintain and Troubleshoot the System When to Use this Chapter This chapter provides a variety of procedures to assist as you commission and operate your redundancy system How to Use this Chapter If you want to Then see this section Which starts on page diagnose the cause of an unplanned switchover Determine the Cause of a Switchover 5 2
51. ay RSLinx software 2 From the Communications menu choose RSWho 3 Expand the network until you see the 1757 SRM module in the primary chassis Workstation Linx Gateways Ethernet AB_KTC x ControlNet n 1756 CNB D Backplane 1756 Ax XX 1757 SRM 4 Right click the 1757 SRM module and choose Module Configuration 5 Check the Synchronization tab 1757 SRM REDUNDANCY MODULE a Click the Synchronization tab Module Info Configuration Synchronization Synchronization Status Event Log Commands Synchronize Secondary Disqualify Secondary Initiate Switchover Recent Synchronization Attempts Order Result Cause b Look here J Success N 1 Success N 2 Synchronization not attempted Ifthe Resultcolumn Then synchronization failed for this reason So take this corrective action shows Edit Session in Progress Synchronization failed for any of these reasons Either e Another workstation is editing the project in e Stop the edit session the controller e Untest the edits The project contains test edits e Close the Nonvolatile Memory Load Store e The Nonvolatile Memory Load Store dialog dialog box box of the controller is open Publication 1756 UM523C EN P June 2003 5 6 Maintain and Troubleshoot the System Manually Synchronize the After a switchover you may have to manual
52. ble revision of firmware e See the ControlFLASH Firmware Upgrade Kit User Manual publication 1756 6 5 6 e To find the chassis in RSLinx software use the node number that the CNB module in the chassis displays Turn off the power to the chassis Turn on the power to the second redundant chassis Wait for the 1757 SRM module to display PRIM Flash upgrade each module in the chassis with a compatible revision of firmware Use the same revisions that you used for the first redundant chassis Publication 1756 UM523C EN P June 2003 3 10 Install the System Synchronize the Controllers To synchronize the controllers in the redundant chassis pair To expand a network one level do one of the following e Double click the network e Select the network and press the key e Click the sign Publication 1756 UM523C EN P June 2003 Q Set the Auto Synchronization Option to Always Synchronize the Controllers Set the Auto Synchronization Option to Always 1 Open RSLinx software 2 From the Communications menu choose RSWho Workstation Linx Gateways Ethernet AB_KTC x ControlNet 3 Navigate to the CNB module of the primary chassis The primary chassis uses the node to which its rotary switches are set primary chassis pe Workstation Linx Gateways Ethernet AB_KTC x ControlNet
53. c in lower priority tasks may experience an upset when a switchover occurs This has to do with how data crossloads from the primary controller to the secondary controller As the primary controller executes its logic it updates the secondary controller at the end of every program interruption by the program end of the program in a in a higher priority task higher priority task start of the program in the lower priority task e g the continuous task primary controller end of the program in the lower priority task ay A A The following data is sent to the secondary controller e data from the program in the higher priority task e data from the first part of the program in the lower priority task B Execution returns to the program in the lower priority task C Data from the second part of the program in the lower priority task is sent to the secondary controller Publication 1756 UM523C EN P June 2003 4 16 Configure and Program the Controller When a switchover interrupts the execution of the primary controller the secondary controller re executes an interrupted program from the beginning of the program interruption by the program end of the program ina in a higher priority task higher priority task start of the program in the lower priority task e g the continuous task oy controlar A e This portion of the task is not executed P ry
54. cation 1756 UM523C EN P June 2003 A array 4 11 auto synchronization 5 18 Basic Operation 1 1 bill of materials A 1 BOM A 1 BOOL 4 11 BSL instruction 4 15 BSR instruction 4 15 C chassis install 3 4 CNB module 4 character display 5 13 connection 2 6 install 3 5 node assignment 2 7 requirements 2 3 statistics 5 11 usage 5 11 communication optimize 5 7 connection 2 6 consumed tag configure 4 7 controller connection 2 6 disqualify secondary 5 31 download project 3 12 install 3 5 nonvolatile memory 5 30 periodic task 5 10 program scan time 4 9 4 10 project 4 1 requirements 2 3 synchronize 3 10 5 6 system overhead time slice 5 8 watchdog time 4 20 ControlNet network addresses 1 6 general lay out 2 2 keeper signature 3 16 5 4 node assignments 2 7 NUT 2 9 redundant media 2 5 schedule 3 13 ControlNet node addresses 1 6 Index conversion to redundant system B 1 crossload 1 4 1 5 D data crossload 1 5 integrity 4 15 organize 4 11 data type recommendations 4 10 4 11 DeviceNet network design 1 7 2 4 DINT 4 11 disqualified overview 1 4 disqualify secondary chassis 5 31 download 3 12 E estimate program scan time 4 9 EtherNet IP network design 1 7 2 4 event log export 5 15 export event log 5 15 F FFU instruction 4 15 firmware update 3 9 5 31 G Get System Value instruction 5 20 GSV instruction 5 20 H HMI configure tags 4 8 design recommendations 2 2 optimize communication
55. cation engineers e instrumentation technicians Use this manual throughout the life cycle of a redundancy system e design e installation e configuration programming e testing e maintenance and troubleshooting This manual is divided into the basic tasks that you perform during the design development and implementation of a ControlLogix redundancy system e Each chapter covers a task e The tasks are organized in the sequence that you will typically perform them As you use this manual you will see some text that is formatted differently from the rest of the text Text that is Identifies For example Means Italic the actual name of an item that you Right click User Defined Right click on the item that is named see on your screen or in an example User Defined courier information that you must supply Right click You must identify the specific program in based on your application a name of program your application Typically it is a name or variable variable that you have defined enclosed in brackets a keyboard key Press Enter Press the Enter key Publication 1756 UM523C EN P June 2003 Preface 2 Notes Publication 1756 UM523C EN P June 2003 ControlLogix Redundancy Overview Design the System Install the System Table of Contents Chapter 1 IM OCMCUOM 424 ko hanes ah Cok ea eed Rae cae Se 1 1 Basic Operation m s 3 35 un 4 4 Bee n a 2na EE 6 e 1 1 SWICROVET s enih ae
56. ch position of the keyswitch of PartnerKeyswitch DINT GSV If Then the keyswitch is in the partner 0 unknown 1 RUN 2 PROG 3 REM status of the minor faults of PartnerMinorFaults DINT GSV This Means this minor fault the partner if the bit ModuleRedundancyState 7 indicates that d bin is 4 problem with an instruction program present 6 periodic task overlap watchdog 9 problem with the serial port 10 low battery mode of the partner PartnerMode DINT GSV If Then 16 0 power up 16 1 program 16 2 run 16 3 test 16 4 faulted 16 5 run 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 PhysicalChassisID INT GSV If Then chassis identification of a 0 k specific chassis without ES regard to the state of the 1 Chassis A u 2 Chassis B slot number of the SRMSlotNumber INT GSV 1757 SRM module in this chassis Publication 1756 UM523C EN P June 2003 5 22 Maintain and Troubleshoot the System For this information Get this attribute Data GSV SSV Description Type Number of DINTs that were LastDataTransfer DINT GSV This attribute is only valid on a primary controller that is or would have been Size configured for redundancy penne If Then this value is the a synchronized amount of data that was last partner is present transferred to the partner specified in DINTs no partner is pres
57. ctions publication 1756 INO80 1756 PA72 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 1756 5 78 1756 L55M13 L55M14 or L55M16 controller ControlLogix Controller and Memory Board Installation Instructions publication 1756 IN101 1756 CNB D or CNBR D module ControlLogix ControlNet Bridge Installation Instructions publication 1756 IN571 1757 SRM module Publication 1756 UM523C EN P June 2003 ProcessLogix ControlLogix System Redundancy Module Installation Instructions publication 1757 IN092 Installation instructions provide important information such as detailed installation steps safety considerations enclosure requirements and hazardous location information Before you install the system review the following guidelines for safe handling of ControlLogix components When you insert or remove a module while backplane power is on an electrical arc can occur This could cause an explosion in hazardous location installations Be sure that power is removed or the area is nonhazardous before proceeding Repeated electrical arcing causes excessive wear to contacts on both a module and its mating connector Worn contacts may create electrical resistance that can affect module operation Install the System 3 3 MATE Preventing Electrostatic Discharge
58. data into arrays is to convert the tags to alias tags for elements of an array as shown below Vv Bool_Tag_2 Bool_Tag_3 Same BOOLs but packed into an array Publication 1756 UM523C EN P June 2003 Tag Name 3 Alias For Base Tag Type Bool_ rray BOOL 32 Bool_Taq_1 Bool_Array 0 Bool_Array 0 BOOL Bool_Tag_2 Bool_Array 1 Baol_Array 1 BOOL Bool_Tag_3 Bool_Array 2 Bool_Array 2 BOOL 2 Bool_Tag_1 Bool_Tag_2 lt Bool_Array 0 gt lt Bool_Array 1 gt 1 Create a BOOL array 2 Convert your BOOL tags to aliases for elements within the BOOL array 3 In your logic continue to reference the existing tag names The system crossloads the Base tag which in this example is the array of BOOLs The array is more compact than the individual tags Configure and Program the Controller 4 13 Execute Instructions Only When Required Anytime an instruction writes a value to a tag even if it is the same value the primary controller crossloads the value to the secondary controller e Many instructions write a value to a tag whenever they execute For example instructions such as OTL OTU and many instructions with Destination operands write a value each time the rung condition in is true e Whenever an instruction writes a value the controller marks the value for the next crossload This occurs even if the instruction wrote the same value that
59. data to be crossloaded measured in 4 byte words In addition a task time that is less than the crossload time could flood the SRM module with data When this occurs the SRM module pauses for approximately 5 ms to clear the overflow buffer This adds 5 ms to the scan time To determine the amount of crossload data use a GSV instruction to access the REDUNDANCY object only available for a controller that is configured for redundancy For more information see Get System Values on page 5 20 Publication 1756 UM523C EN P June 2003 4 10 Configure and Program the Controller Minimize Scan Time To minimize the scan time of your project follow these guidelines Use a Few Large Programs Minimize the Use of SINT or INT tags Use Arrays and User Defined Data Types Pack Data into Arrays U DD Execute Instructions Only When Required Use a Few Large Programs Since the primary controller pauses its execution at the end of every program to crossload data combine your logic into a few relatively large programs instead of many smaller programs e A fewer number of programs requires fewer crossloads e Larger programs pack more data into each crossload since more logic will have executed before the crossload Divide each program into whatever number of routines makes the most sense for your logic The number of routines have no effect on the frequency of crossloads Minimize the Use of SINT or INT tags Regardless
60. determine why the secondary controller fails to synchronize Troubleshoot a Failure to Synchronize 5 3 initiate the synchronization process Manually Synchronize the Controllers 5 6 e determine why it takes a very long time to Optimize Communication 5 7 synchronize the secondary controller e determine why communication with your HMIs is very slow e determine the CPU usage of a CNB module Adjust CNB Usage 5 11 e reduce the CPU usage of a CNB module export specific events from the SRM event log and view them Export the SRM Event Log to Microsoft 5 15 in a Microsoft Excel spreadsheet Excel change when the 1757 SRM modules try to synchronize the Configure the Auto Synchronization 5 18 controllers Option use ladder logic to get system or status information about Get System Values 5 20 your redundancy system use ladder logic to initiate a redundancy action such as Send a Message to an SRM Module 5 24 synchronize the secondary controller e store a project to the nonvolatile memory of a Store or Load a Project Using Nonvolatile 5 30 controller in a redundant system Memory e load a project into the controller from the nonvolatile memory of the controller change the revision of a module while minimizing the time Update a Module 5 31 your system is off Publication 1756 UM523C EN P June 2003 5 2 Maintain and Troubleshoot the System Determine the Cause of a Switchover determine the cause of the switchover If an unplanned switchover occurs u
61. djust CNB WS AOC gags dy hi kk kK Gute KK RIK KI KK KI A KIRI KI KK KI Se oes 5 11 Use RSLinx Software Las A kK KK KI KRI KI KI KI KI KI KI KK 5 12 Look at the Four Character Display 5 13 Develop the Bill of Materials Convert an Existing System to Redundancy Table of Contents 3 Send a Message to the CNB Module 5 14 Export the SRM Event Log to Microsoft Excel 5 15 Export Events to a CSV Filet bat ons vien 5 15 Open and Format the CSV File 5 17 Configure the Auto Synchronization Option 5 18 Choose an Auto Synchronization Option 5 18 Configure the Auto Synchronization Option 5 18 Get System Values LE denis panne ee ahd naa ee na 5 20 Send a Message to an SRM Module 5 24 Configure the 1757 SRM Module 5 25 Enter the Message Instruction 5 26 Configure the Message Instruction 5 27 Store or Load a Project Using Nonvolatile Memory 5 30 Update a Mod le er ciseu on Sa dD y die Ar OR E 5 31 Disqualify the Secondary Chassis 5 31 Upgrade the Required Firmware of the Secondary Chassis 5 92 Make the Secondary Controller the New Primary Controller 5 33 Upgrade the Other Redundant Chassis 5 33 Change the Auto Synchronization Option to ALWAYS 5 34 Appendix A Redundant Controller Chassis A 1 Additional Materials LA A
62. dule for all Connections button default and choose OK Publication 1756 UM523C EN P June 2003 3 16 Install the System Check the Keepers On a ControlNet network each keeper must e be able to take over the keeper duties if the current keeper drops off the network e use the same configuration signature regardless of which keeper comes online first after a major network disturbance cable short system power cycle etc After you schedule your ControlNet networks 1 2 Y Y Keeper Capable Node Active Keeper Valid Keeper offline file N A N A 01 NO YES 02 YES YES 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 5 4 Save the Project for Each Controller After your schedule your ControlNet networks save the online project of each controller This lets you download a project in the future without having to reschedule the networks For each controller redundant and non redundant on a ControlNet network 1 Go online to the controller 2 Save the project Publication 1756 UM523C EN P June 2003 Test the Switchover ControlNET ED ot al n Ol A a Click the Configuration tab 43130 Install the System 3 17 To test a switchover use RSLinx software to manuall
63. during this scan e If an instruction was executing at the time of the switchover it does not complete in switchover this scan occurs secondary controller A The following data is sent to the secondary controller e data from the program in the higher priority task e data from the first part of the program in the lower priority task B Execution returns to the program in the lower priority task C The secondary controller e starts the scan at the beginning of the program that was in progress in the primary controller at the time of the switchover e uses the 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 last scan of the primary controller Publication 1756 UM523C EN P June 2003 Configure and Program the Controller 4 17 To find places in your logic that might be susceptible to an upset during a switchover Look for Array Shift Instructions Look for Logic That is Scan Dependant Q Take Preventative Actions Look for Array Shift Instructions The following instructions might corrupt your data during a switchover e BSL e BSR e FFU Because these instructions shift data within an array an interruption by a higher priority task and a subsequent switchover leaves the data with an incomplete shift e If a higher priority task interrupts one of these instructions the partially shift
64. e Har Publication 1756 UM523C EN P June 2003 4 6 Configure and Program the Controller Configure Communications A redundant system requires some specific configuration choices for successful communications Use this section for guidance on how to configure the following elements for redundancy Configure I O Configure Produced Tags Configure Message MSG Instructions Configure Tags for an HMI Configure 1 0 TONNES For each module in your system make sure that the requested packet interval RPD is less than or equal to 375 milliseconds If you use a larger RPI the controller could lose its connection with the module during a switchover This could cause outputs to change state For any outputs that require a bumpless switchover e Put those outputs in the highest priority task e Configure only that task at the highest priority Publication 1756 UM523C EN P June 2003 Configure and Program the Controller 4 7 Configure Produced Tags Tiina During a switchover the connection for tags that are consumed from a redundant controller may time out e The data does not update e The logic acts on the last data that it received After the switchover the connection reestablishes and the data begins to update again If you want a controller in another chassis to consume a tag from the redundant controller use a comm format of None In the I O configuration of the consuming controller select a
65. ed array values are sent to the secondary controller e If a switchover occurs before the instruction completes its execution data remains only partially shifted e The secondary controller starts its execution at the beginning of the program When it reaches the instruction it shifts the data again Publication 1756 UM523C EN P June 2003 4 18 Configure and Program the Controller Publication 1756 UM523C EN P June 2003 Look for Logic That is Scan Dependant A rung that must read the output of another rung during the same scan might miss a scan during a switchover For example CTU Count Up Counter scan_count Preset 1000 Accum 0e scan_count CU EQU Equal Source scan_count ACC 0e Source B 1000 43065 A The CTU instruction counts each scan B The EQU instruction uses the count of each scan scan_count ACC C If a higher priority task interrupts the logic the value of scan_count ACC is sent to the secondary controller at the end of the program in the higher priority task D If a switchover occurs before the EQU instruction the secondary controller starts its execution at the beginning of the program The EQU instruction misses the last value of scan_count ACC Configure and Program the Controller 4 19 Take Preventative Actions If you find place in your logic that might be susceptible to an upset during a switchover take one of the following prev
66. edia Redundant ControlNet media prevents a loss of communication if a trunkline or tap is severed or disconnected It uses the following components e 1756 CNBR ControlNet modules e two identical ControlNet links ControlLogix chassis with 1756 CNBR module r ControlNet node redundant media ra 2 ole T 2 raja oe A ControlNet node Publication 1756 UM523C EN P June 2003 2 6 Design the System Redundant Power Supplies Redundant power supplies let you maintain power to a ControlLogix chassis if a power supply fails Redundant power supplies use the following hardware e two redundant power supplies any combination of 1756 PA75R and 1756 PB75R e 1756 PSCA chassis adapter module in place of the standard power supply e two 1756 CPR cables to connect the power supplies to the 1756 PSCA adapter e user supplied annunciator wiring to connect the power supplies to the input modules if needed 1756 PA7ER or 1756 PA75R or 1756 PB75R DD 1756 PB75R 1756 CPR cable 1 6 ie D D annunciator wiring a 1756 digital ControlLogix chassis with input module 1756 PSCA module Check Connection Make sure that each controller in a redundant chassis has available Requirements e
67. emote chassis or DIN rails no 1 0 in the local chassis 2 2 2 4 e All 1 0 in only the following locations e same ControlNet network as the redundant controllers no bridging e DeviceNet network via a 1756 DNB module in a remote chassis e universal remote 1 0 network via a 1756 DHIRO module in a remote chassis 5 Number of At least 2 nodes on each network in addition to the CNBs in the redundant chassis 2 7 ControlNet nodes l e Each ControlNet network has at least 4 nodes 6 ControlNet node assignments Non redundant nodes use the lowest node numbers 1 B 2 7 CNB modules in the redundant chassis set close to the SMAX 2 consecutive node addresses for each set of partner CNB modules one in each chassis Switches of each partner CNB module set to the same node address Q 7 PanelView e lt 3 terminals per CNB module 2 2 terminals e lt 4 terminals per controller Q 8 Network Access No devices connected to the network access ports of CNB modules in the redundant 2 2 Ports chassis Publication 1756 UM523C EN P June 2003 1 8 ControlLogix Redundancy Overview Redundant Chassis Configuration Parameter Criteria See page Q 1 Chassis size Same size chassis for each pair of redundant chassis 2 9 2 Chassis lay out e Only the following modules in each redundant chassis no other modules 2 9 e 1 controller e 1 to 5 CNB modules e 1 SRM module req
68. ent amount of data that would have been di ified vart last transferred to a synchronized RE A parner partner specified in DINTs is present Maximum number of DINTs MaxDataTransfer DINT GSV Maximum value of the LastDataTransfer Size attribute that were or would have Size been transferred SSV e This attribute is only valid on a primary controller that is Publication 1756 UM523C EN P June 2003 configured for redundancy e To reset this value use an SSV instruction with a Source value of 0 If Then this value is the a synchronized maximum amount of data that was partner is present transferred to the partner specified in DINTs no partner is present maximum amount of data that would have been last transferred to a a disqualified partner synchronized partner specified in is present DINTs For more information on the status information that you can access with the GSV instruction see Logix5000 Controllers General Instructions Reference Manual publication 1756 RM003 Maintain and Troubleshoot the System 5 23 EXAMPLE Get system values The first GSV instruction gets the label of the chassis that is currently the primary chassis and stores the value in redundant_ID The second GSV instruction gets the redundancy state of the controller and stores the value in redundant state GSV Get System Value Class name REDUNDANCY Instance name Attribute Name PhysicalChassislD Dest redundant_ID 16 0000_0000
69. entative actions 1 Place Susceptible Logic in the Highest Priority Task 2 If the logic must remain in a lower priority task take one of the following actions e Use UID and UIE Instruction Pairs e Buffer Critical Data Place Susceptible Logic in the Highest Priority Task e This prevents the controller from sending any data to the secondary controller until the program finishes e If a switchover occurs during the program the secondary controller repeats the scan using the same starting data Use UID and UIE Instruction Pairs Bound critical rungs with UID and UIE instruction pairs This prevents the higher priority task form interrupting the scan dependent logic as shown below ID gt CTU Count Up Counter scan_count Preset 1000 Accum 0e scan_count CU EQU Equal Source scan_count ACC D l Source B 1000 UIES Publication 1756 UM523C EN P June 2003 4 20 Configure and Program the Controller Buffer Critical Data The following example shows the use of a buffer together with a BSL instruction Vy j photoeye CO BSL CPS Copy File Bit Shift Left Synchronous Copy File Source array 0 Array array_buffer 0 Source array_buffer 0 Dest array_buffer 0 Control Dest array 0 2 Length 2 Length Source Bit input_bit Length 64e 43065 1 The COP instruction moves the data into a buffer array 2 The BSL instruction uses
70. es 1 Start RSLinx software 2 From the Communications menu choose RSWho 3 Expand the network until you see the SRM module in the primary chassis Workstation Linx Gateways Ethernet AB_KTC x ControlNet xx 1756 CNB D Backplane 1756 Ax gt xx 1756 module 1757 SRM 4 Right click the 1757 SRM module and select Module Configuration 5 Click the Configuration tab 6 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Options Auto Synchronization Always O gt SRM Seri Name Descriptio Chassis ID Chassis B gt Location IV Enable User Program Control 6 Select the Enable User Program Control check box This is the default setting 7 Choose OK Publication 1756 UM523C EN P June 2003 5 26 Maintain and Troubleshoot the System Enter the Message Instruction 1 Open the RSLogix 5000 project 2 Enter a MSG instruction and associated input instruction s MSG Message Message Control CEND DN CERD i 42424 3 In the MSG instruction type a name for the message control tag In the MSG instruction right click the message control tag and MSG Type Unconfigured Message Control e condition e J J E e e e e and press the Enter key 4 select New tag_name e
71. es in the secondary chassis use Workstations and HMIs connect to the node number of the primary chassis Publication 1756 UM523C EN P June 2003 the node number to which they are set plus 7 node numbers with its partner in Each pair of CNB modules are set to the same node number switchover 24 the other chassis secondary chassis 25 CNB modules swap node numbers primary chassis CNB modules swap node numbers Workstations and HMIs continue to connect to the same node number ControlLogix Redundancy Overview 1 7 Quick Start Checklists The following checklists provide a summary of the criteria for a successful ControlLogix redundancy system See the remaining chapters for more information on each parameter System Lay Out Parameter Criteria See page Q 1 Type of network ControlNet networks are the primary networks for the system OK to bridge to devices 2 2 on other networks such as EtherNet IP DeviceNet Universal Remote 1 0 and DH networks Q 2 Number of Separate ControlNet networks for scheduled communications I O produced consumed 2 2 ControlNet networks tags and unscheduled communications HMI workstations message instructions Q 3 Network update e NUTs lt 90 ms 2 9 times e NUTs lt specified relationship to each other 4 1 0 Placement e All 1 0 modules in r
72. es on how to lay out a system Chapter 2 Recommendations for the number of ControlNet networks Recommendations for the number of PanelView terminals Restrictions on the networks for 1 0 Optional components for a redundancy system Restrictions on the use of a network access port NAP Chapter 3 Download a project Schedule a ControlNet network When to retain test edits Chapter 4 How to estimate scan time Tips to minimize scan time Troubleshoot a failure to synchronize Chapter 5 Update keeper signatures Tips to optimize communication performance Interpret the 4 character display of a CNB module Export SRM events to Microsoft Excel Get system values reorganized to make it easier to use Store or load a project using nonvolatile memory Bill of materials moved to an appendix Appendix A Convert an non redundant system to a redundant system moved to an appendix Appendix B Glossary of common terms Glossary Publication 1756 UM523C EN P June 2003 Summary of Changes 2 Notes Publication 1756 UM523C EN P June 2003 Purpose of this Manual Who Should Use this Manual When to Use This Manual How to Use this Manual Preface This manual guides the design development and implementation of a redundancy system for a ControlLogix controller This manual is intended for those individuals who design and develop applications that use ControlLogix controllers such as e software engineers e control engineers e appli
73. he lowest node numbers TT N l 0 modules nial V network via a NAP use a remote to non redundant nodes d B BIR noce 0 BB at least 2 nodes in EL neONOINS addition to the CNBs in the redundant chassis An additional node can be a e second CNB module in the same remote chassis or in a different remote chassis ps a D e any other ControlNet device not required to be keeper capable e workstation that is running RSLinx software Publication 1756 UM523C EN P June 2003 Design the System 2 3 Figure 2 2 ControlLogix redundancy requirements and recommendations Continued _____ 1756 CNB D or CNBR D module or modules 1756 L55M13 L55M14 L55M16 L55M23 or L55M24 controller e Only 1 in each redundant chassis e Requires enough memory for 2 copies of all data e Requires 7 connections for redundancy e 1 5 in each redundant chassis Keep CPU usage lt 75 Allocate 2 consecutive node addresses for each set of partner CNB modules one in each chassis e Assign each partner CNB module to the same node address Assign the higher node addresses in your system to the CNB modules in the redundant chassis 1757 SRM module e only 1 in each redundant chassis e uses 2 slots vv eee E G redundant 5 N chassis a 5 B M X zoo a no other modules el e same slot number
74. ience a change in state bump during a switchover e During the switchover outputs that are controlled by the highest priority task will experience a bump less switchover i e Outputs will not revert to a previous state e Outputs in lower priority tasks may experience a change of state The switchover time of a redundant system depends on the type of failure and the network update time NUT of the ControlNet network For a NUT of 10 ms the switchover time is approximately 80 ms to 220 ms Publication 1756 UM523C EN P June 2003 1 4 Controllogix Redundancy Overview Synchronization Term crossload To take over control the secondary controller requires the same project as the primary controller It also requires up to date tag values The following terms describe the process of communication between the two controllers Description The transfer of any or all of the contents of the primary controller to the secondary controller This could be updated tag values force values online edits or any other information about the project A crossload occurs initially when the controllers synchronize and then repeatedly as the primary controller executes its logic synchronize The process that readies a secondary controller to take over control if a failure occurs in the primary chassis During synchronization the 1757 SRM modules check that the partner modules in the redundant chassis pair are compatible with e
75. igure Tags for an HMI oaao KK KK 4 8 Estimate the Scan Time of a Program 4 9 Minimize Scan Time EAN AE ge ey Dake a 4 10 Use a Few Large Programs 2 21 ox oH doh odo dies 4 10 Minimize the Use of SINT or INT tags 4 10 Use Arrays and User Defined Data Types 4 11 Pack Data into Arrays ou lues tiens 4 11 Execute Instructions Only When Required 4 13 Maintain the Integrity of Your Data During a Switchover 4 15 Look for Array Shift Instructions 4 17 Look for Logic That is Scan Dependant 4 18 Take Preventative ACHONS ai elles ae de KK IK 4 19 Set the Task Watchdog Times ea dures date RR KK 4 20 Estimate a Watchdog Time 4 20 Set the Watchdog Time for a Task 4 21 Determine the Scan Time of a Task icv taeda 4 22 Chapter 5 When to Use this Chapter EL re tin mer KII KK 5 1 How to Use this Chapter 5 1 Determine the Cause of a Switchover 5 2 Troubleshoot a Failure to Synchronize 5 3 Update a Keeper Signature 85 ea aa tient a 5 4 Check the Recent Synchronization Attempts 5 5 Manually Synchronize the Controllers 5 6 Optimize Communication SMS eee eek ps 5 7 Choose a Greater System Overhead Time Slice 5 8 Enter a System Overhead Time Slice 5 9 Make All Your Tasks Periodic i oy ads en 24 PAY Eos 5 10 A
76. imary In RSLogix 5000 software go online to the new primary controller The controller is faulted When a disqualified secondary controller becomes a primary controller the controller experiences a major fault From the Communications menu choose Clear Faults To start control of the process from the Communications menu choose Run Mode Upgrade the Other Redundant Chassis 1 2 Turn on power to the other redundant chassis Upgrade the required firmware of the chassis Publication 1756 UM523C EN P June 2003 5 34 Maintain and Troubleshoot the System Change the Auto Synchronization Option to ALWAYS 1 Go to RSLinx software 2 Find the SRM module in the primary chassis and open the properties of the module 3 On the Configuration tab change the Auto Synchronization Option to ALWAYS 4 Choose OK Publication 1756 UM523C EN P June 2003 Appendix A Redundant Controller Chassis Additional Materials Y Oty Item chassis or DIN rails Develop the Bill of Materials The ControlLogix redundancy system requires the following hardware for your controllers Y Qty Item Cat number 2 chassis 1756 A4 A7 A10 A13 or A17 2 power supply 1756 PA72 PB72 PA75 or PB75 2 controller 1756 L55M113 L55M14 L55M16 L55M23 or L55M24 2 ControlNet bridge 1756 CNB D or CNBR D module 2 redundancy module 1757 SRM 1 fiber optic cable 1757 SRC1 SRC3
77. in and Troubleshoot the System Secondary 42797 Publication 1756 UM523C EN P June 2003 Update a Keeper Signature If the secondary chassis fails to synchronize and its CNB module displays Cpt the keeper signature of a CNB module may not match its partner This occurs if you schedule the ControlNet network while the secondary chassis is off or if the CNB module was previously configured in a different network 1 Start RSNetWorx for ControlNet software 2 Has this network been scheduled before If Then No A From the File menu select New B From the Network menu select Online C Select your ControlNet network and choose OK Yes A From the File menu select Open B Select the file for the network and choose Open C From the Network menu select Online 3 From the Network menu choose Keeper Status 4 5 f Y Keeper Capable Node Active Keeper Valid Keeper offline file N A N A 01 NO NO 02 YES YES 4 Make sure the list contains all keeper capable nodes 5 Make sure that each node has a valid keeper signature If the Valid Keeper column Then shows YES The node has a valid keeper signature NO Select the node and choose Update Keeper 6 Choose Close Maintain and Troubleshoot the System 5 5 Check the Recent Synchronization Attempts 1 Displ
78. lNet node powers down at the same time e g a plant wide power loss you may have to cycle the power to the primary chassis to restore communication Publication 1756 UM523C EN P June 2003 2 8 Design the System 3 Allocate two consecutive ControlNet addresses for each pair of redundant chassis e g nodes 3 and 4 e If each redundant chassis has multiple CNB modules assign a pair of node numbers for each pair of CNB modules one in each chassis e Do not configure any other device on the ControlNet network for either of these addresses For example if you allocated nodes 3 and 4 for the redundant chassis then no other device should use those node numbers Use the following worksheet to record the slot number and node numbers for each pair of CNB modules Table 2 1 Slot and node numbers for 1756 CNB D or CNBR D modules Pair of CNB modules one in each Slot and node numbers kedundant chassis Slot Primary node Secondary node primary node 1 1st pair of CNB modules 2nd pair of CNB modules 3rd pair of CNB modules Ath pair of CNB modules 5th pair of CNB modules Publication 1756 UM523C EN P June 2003 Select a Network Update Time If you have only one CNB module in a redundant chassis Design the System 2 9 Use a network update time NUT that is less than or equal to the following values And Then Use a NUT that is less than or equal to 9
79. lautomation com you can Support find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect Support programs For more information contact your local distributor or Rockwell Automation representative or visit http 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 this manual You can also contact a special Customer Support number for initial help in getting your module up and running United States 1 440 646 3223 Monday Friday 8am 5pm EST Outside United Please contact your local Rockwell Automation representative for any States technical support issues New Product Satisfaction Return Rockwell tests all of our products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned United States Contact your distributor You must provide a Customer Support case number see phone number above to obtain one to your distributor in order to complete the return process Outside United Please contact
80. llers Never You can still manually synchronize the controllers Configure the Auto Synchronization Option 1 Display RSLinx software 2 From the Communications menu choose RSWho To expand a network one level do one of the following e Double click the network e Select the network and press the key e Click the sign Workstation Linx Gateways Ethernet AB_KTC x ControlNet 3 Navigate to the CNB module of the primary chassis The primary chassis uses the node to which its rotary switches are set primary chassis Workstation TT Linx Gateways Ethernet AB_KTC x ControlNet n 1756 CNB D Publication 1756 UM523C EN P June 2003 Maintain and Troubleshoot the System 5 19 4 Expand the CNB module of the primary chassis 5 Expand the backplane Workstation Linx Gateways Ethernet AB_KTC x ControlNet n 1756 CNB D Backplane 1756 Ax gt XX 1756 module 1757 SRM 6 Right click the 1757 SRM module and select li Module Configuration 7 Click the Configuration tab 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Ever Options 8 Auto Synchronization ANAIS SRAM Serial Numt Name 8 Choose the Auto Synchronization o
81. ly synchronize the Controllers controllers because either e The Auto Synchronization option is NOT set to Always e The controllers failed to synchronize To manually synchronize the controllers 1 Display RSLinx software 2 From the Communications menu choose RSWho 3 Expand the network until you see the 1757 SRM module in the primary chassis Workstation Linx Gateways Ethernet AB_KTC x ControlNet n 1756 CNB D Backplane 1756 Ax gt xx 1756 module 1757 SRM 4 Right click the 1757 SRM module and select Module Configuration 5 Click the Synchronization tab 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log Commands Synchronize Secondary Disquali Secondary Initiate Suvitchover Become Primary 6 6 Choose Synchronize Secondary and then choose Yes to confirm 7 Choose OK Publication 1756 UM523C EN P June 2003 li Front Panel ControlNET Look here pel m m 319 Ol a 43130 Optimize Communication PwQOg Primary with Synchronizing Maintain and Troubleshoot the System 5 7 8 In the primary chassis what do the CNB modules display lf you see Which means Then e Synchronization is in progress Qualifying Secondary e
82. man 2 2 Choose Initiate Switchover and then choose Yes to confirm Make Sure the Controllers are Synchronized If you set the Auto Synchronization option to Always the SRM modules try to synchronize the controllers after a switchover 1 To monitor the synchronization progress click the Synchronization Status tab 1757 SRM REDUNDANCY MODULE s1 Event Log derez Module Info Configuration Synchronization lete Module Secondary Readiness Compatibility 0 1756 L55 Synchronizing Primary Full lt empty gt lt empty gt lt empty gt a 19 1756 CNBR Synchronizing Primary Full B lt empty gt lt empty gt lt empty gt a E 0 1757 SRM Disqualified Primary Full JD I amp Co J If the controller contains a large project the system may spend some time synchronizing the secondary controller 2 If the Secondary Readiness remains Disqualified see Troubleshoot a Failure to Synchronize on page 5 3 Publication 1756 UM523C EN P June 2003 When to Use this Chapter How to Use this Chapter Chapter 4 Configure and Program the Controller After you have installed your system use this chapter to configure and program the controller for redundancy IMPORTANT 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
83. me interval in which data is sent over the ControlNet network Max Scheduled Address greatest node number to use scheduled communications on the network Max Unscheduled Address greatest node number that you will use on the network Media Redundancy channels in use Network Name Publication 1756 UM523C EN P June 2003 10 11 12 13 name for the network choose OK From the Network menu choose Single Pass Browse From the File menu choose Save Type a name for the file that stores the network configuration then choose Save Select the Optimize and re write Schedule for all Connections button default and choose OK Install the System 3 15 Update the Schedule of an Existing Network 1 In this box Turn on the power to each chassis Start RSNetworx for ControlNet software From the File menu choose Open Select the file for the network and choose Open From the Network menu choose Online Select the Edits Enabled check box From the Network menu choose Properties From the Network Parameters tab update the following parameters Specify Max Scheduled Address greatest node number to use scheduled communications on the network Max Unscheduled Address 10 11 12 greatest node number that you will use on the network choose OK From the Network menu choose Single Pass Browse From the File menu choose Save Select the Optimize and re write Sche
84. n remote chassis or on DIN rails The following example shows a remote 1756 chassis You can use any type of chassis or device that you can connect to the ControlNet network EtherNet IP network PC TN S ERN C E R N 1 0 modules N M B B 42197 other ControlNet node s You must have at least 2 other nodes in addition to the redundant chassis pair See Lay Out the System on page 2 2 IMPORTANT If you connect the workstation to the network via a network access port on a CNB module use a CNB module in a remote chassis This lets a switchover occur after the failure of a ControlNet tap of a primary chassis Publication 1756 UM523C EN P June 2003 As you install the chassis follow these guidelines e Do not assign any device to the address of the CNB modules in the redundant chassis plus one 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 e Use a remote chassis for communication modules such as 1756 ENET or ENB 1756 DHRIO 1756 MVI 1756 DNB Flash the Modules Redundancy Module 42801 Install the System 3 9 Turn on the power to one of the redundant chassis Wait for the 1757 SRM module to display PRIM Flash upgrade each module in the chassis with a compati
85. nough connections for redundancy communications Redundancy q communications require the following number of additional connections This module Uses this many additional Description connections for redundancy controller 7 2 for the SRM 5 for the partner Publication 1756 UM523C EN P June 2003 Design the System 2 7 Assign ControlNet Addresses 1 Make sure that your network has at least 2 nodes in addition to IMPORTANT the redundant chassis pair An additional node can be a e second CNB module in the same remote chassis or in a different remote chassis e any other ControlNet device e workstation that is running RSLinx software If your ControlNet network 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 switchover 2 Assign the lowest ControlNet addresses to I O chassis and other IMPORTANT remotely located chassis Le Do not assign the lowest addresses to the redundant chassis pair If you assign the lowest address to a CNB module in the redundant chassis pair e On a switchover you may temporarily lose communication with I O modules produced tags and consumed tags e If you remove the CNB module from the primary chassis while chassis power is on you may temporarily lose communication with I O modules produced tags and consumed tags e If every Contro
86. ocks fewer blocks may be required than if the same amount of data was spread across many individual tags To create arrays and user defined data types see the Logix5000 Controllers Common Procedures publication 1756 PM001 Pack Data into Arrays The minimum memory allocation for a tag is 4 bytes When you create a tag that stores data that requires less than 4 bytes the controller allocates 4 bytes but the data only fills the part it needs Data type Bits 31 16 15 8 7 1 0 Bool not used 0 or 1 Sint not used 128 to 127 Int not used 32 768 to 32767 Dint 2 147 483 648 to 2 147 483 647 Real 3 40282347E 8 to 1 17549435E negative valies 1 17549435E 8 to 3 40282347E positive values Publication 1756 UM523C EN P June 2003 4 12 Configure and Program the Controller BOOLs as individual tags Tag Name Bool_Tag_1 User defined data types and arrays pack smaller data types into 32 bit words For example e If you create 32 individual BOOL tags the controller allocates 128 bytes for the data 32 BOOL tags x 4 bytes tag 128 bytes e If you create an array of 32 BOOLS the controller packs them into a 4 byte chunk of memory Bits 31 0 Bool_Array 31 Bool_Array 0 Arrays provide the greatest advantage with BOOL tags If you have individual SINT INT DINT or REAL tags also use arrays to pack those tags as efficiently as possible One simple way to pack existing
87. ollers 5 6 store a project to nonvolatile memory 5 30 switchover causes 1 2 data integrity 4 15 diagnose cause 5 2 initiate 3 18 test 3 17 time for 2 11 synchronize controllers 5 6 diagnose failure 3 18 overview 1 4 status 3 18 synchronize controllers 3 10 system information get 5 20 system overhead time slice 5 8 T task number of 5 10 watchdog time 4 20 task scan time determine 4 22 test Index 3 switchover 3 17 U update firmware 3 9 5 31 user defined data type 4 11 W watchdong time 4 20 workstation connect to a NAP 1 3 3 1 Publication 1756 UM523C EN P June 2003 4 Index Publication 1756 UM523C EN P June 2003 Glossary connection A communication link between two devices such as between a controller and an I O module PanelView terminal or another controller You indirectly determine the number of connections the controller uses by configuring the controller to communicate with other devices in the system Connections are allocations of resources that provide more reliable communications between devices than unconnected messages See direct connection rack optimization connection consumed tag A tag that receives the data that is produced broadcast by another controller Logix5000 controllers can produce and consume tags over an EtherNet IP network a ControlNet network or a ControlLogix backplane See produced tag crossload The transfer of any or all of the contents of the
88. primary controller to the secondary controller This could be updated tag values force values online edits or any other information about the project A crossload occurs initially when the controllers synchronize and then repeatedly as the primary controller executes its logic direct connection A direct connection is a real time data transfer link between the controller and an I O module The controller maintains and monitors the connection between the controller and the I O module Any break in the connection such as a module fault or the removal of a module while under power causes the controller to set fault status bits in the data area associated with the module See connection rack optimization connection disqualified Indicates that the secondary control has failed to synchronize with the primary controller If a secondary controller is disqualified it is unable to take over control of the machine or process You also have the option of manually disqualifying a secondary controller load To copy a project from nonvolatile memory to the user memory RAM of the controller This overwrites any project that is currently in the controller See nonvolatile memory store Publication 1756 UM523C EN P June 2003 Glossary 2 Publication 1756 UM523C EN P June 2003 NAP See network access port NAP network access port NAP A port on a ControlNet device that lets you connect another device to a ControlNet network
89. ption If you want the SRM modules to Then choose this Auto Synchronization option always try to synchronize the controllers Always default e always try to synchronize the controllers until Conditional you manually disqualify the secondary chassis e once you disqualify the secondary chassis never try to synchronize the controllers until you manually synchronize the controllers never try to synchronize the controllers Never 9 Choose OK Publication 1756 UM523C EN P June 2003 5 20 Maintain and Troubleshoot the System Get System Values You can use a GSV instruction in your ladder logic to get system values for your redundancy system You can then display that information on an HMI screen The REDUNDANCY object provides the following status information about the redundancy system For this information Get this attribute Data GSV SSV Description Type redundancy status of the ChassisRedundancy INT GSV If Then entire chassis State 6 1 power up or undetermined 16 2 primary with synchronized secondary 16 3 primary with disqualified secondary 16 4 primary with no secondary redundancy state of the PartnerChassis INT GSV If Then partner chassis RedundancyState 1648 synchronized secondary 16 9 disqualified secondary with primary redundancy status of the ModuleRedundancy INT GSV If Then contele aai 16 1 power up or unde
90. s copyrighted publication in whole or part without written permission of Rockwell Automation is prohibited Throughout this publication notes may be used to make you aware of safety considerations The following annotations and their accompanying statements help you to identify a potential hazard avoid a potential hazard and recognize the consequences of a potential hazard Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss IMPORTANT Identifies information that is critical for successful application and understanding of the product Summary of Changes Introduction This release of this document contains new and updated information To find new and updated information look for change bars as shown next to this paragraph Updated Information The document contains the following changes This new or updated information See New chapter that gives an overview of the ControlLogix redundancy system including basic operation Chapter 1 switchover synchronization crossloading handling of ControlNet addresses and quick start checklists Expanded guidelin
91. s to 2 000 000 ms 2000 seconds The default is 500 ms e The watchdog timer begins to time when the task is initiated and stops when all the programs within the task have executed e If the task takes longer than the watchdog time a major fault occurs The time includes interruptions by other tasks Publication 1756 UM523C EN P June 2003 Glossary 6 Notes Publication 1756 UM523C EN P June 2003 How Are We Doing AB Your comments on our technical publications will help us serve you better in the future Thank you for taking the time to provide us feedback xw You can complete this form and mail it back to us visit us online at www ab com manuals or email us at RADocumentComments ra rockwell com Pub Title Type ControlLogix Redundancy System Cat No Pub No 1756 UM523C EN P Pub Date June 2003 Part No 957689 35 Please complete the sections below Where applicable rank the feature 1 needs improvement 2 satisfactory and 3 outstanding Overall Usefulness 1 2 3 How can we make this publication more useful for you 2 3 Can we add more information to help you Completeness all necessary information procedure step le illustration L feature is provided _ example _ guideline L other _ explanation _ definition Technical Accuracy 1 2 3 Can we be more accurate all provided information dlp is correct text F illustration Clarity 1 2 3 How can
92. se the following tables to In the primary chassis what does the CNB module display Front Panel If Then PwNS Go to Table 5 1 wer PwDS Go to Table 5 2 Look here J 43130 Table 5 1 If a CNB module displays PwNS use this table to troubleshoot the secondary chassis If the secondary chassis has power does not have power And each primary CNB And a secondary CNB Then module module has a has a partner module in the Red OK LED Replace the CNB module secondary chassis Green OK LED Check the 1756 SRC cable for a proper connection does not have a partner module Install a CNB module in the secondary chassis _ eer eZ dcedeer _ eera v _ _j _ _ _ _ j Restore the power Table 5 2 If a CNB module displays PwDS use this table to troubleshoot the secondary chassis lf the SRM module And a secondary CNB And a secondary controller Then has a module has a Green OK LED does not display NET ERR Flashing Red OK LED Clear the major fault of the controller Solid Red OK LED 1 Cycle the power to the chassis 2 If the OK LED remains solid red replace the controller and flash the controller with the appropriate revision of firmware displays NET ERR Check all ControlNet taps connectors and SSS terminators for proper connections Red OK LED 1 Cycle the power to the chassis
93. t is greater than zero Publication 1756 UM523C EN P June 2003 5 14 Maintain and Troubleshoot the System On this tab Configuration Send a Message to the CNB Module To use a Message MSG instruction to get the CPU usage of a CNB module configure the MSG instruction as follows For this Type or select Message Type CIP Generic Service Code Af Class name al Instance name 8 Attribute name leave blank Source tag that uses a user defined data type Members of the data type Tag value Name Data type offset DINT 0 size_returned INT 2 Num Of Elements 6 Destination INT tag in which to store the CPU usage of the CNB module 0 99 Communication Path 1 Slot number Publication 1756 UM523C EN P June 2003 where slot number is the slot number of the CNB module Maintain and Troubleshoot the System 5 15 Export the SRM Event Log To export specific events from the SRM event log to a Microsoft Excel spreadsheet to Microsoft Excel Q Export Events to a CSV File Open and Format the CSV File Export Events to a CSV File 1 Display RSLinx software 2 Expand the network until you see the 1757 SRM module in the primary chassis Workstation Linx Gateways Ethernet AB_KTC x ControlNet n 1756 CNB D Backplane 1756 Ax XX 1756 module 1757 SR
94. termined 16 2 primary with synchronized secondary 16 3 primary with disqualified secondary 16 4 primary with no secondary 16 6 primary with synchronizing secondary redundancy state of the PartnerModule INT GSV If Then parmer nes Aie 16 7 synchronizing secondary 16 8 synchronized secondary 16 9 disqualified secondary with primary results of the compatibility CompatibilityResults INT GSV If Then checks with the partner 0 determined controller HURE wee 1 no compatible partner 2 fully compatible partner status of the Qualification INT GSV If Then synchronization InProgress ae Pe qualification process 1 Synchronization qualification is not in progress 0 unsupported 1 99 For modules that can measure their completion percentage the percent of synchronization qualification that is complete 50 For modules that cannot measure their completion percentage synchronization qualification is in progress 100 Synchronization qualification is complete Publication 1756 UM523C EN P June 2003 Maintain and Troubleshoot the System 5 21 For this information Get this attribute Data GSV SSV Description Type keyswitch settings of the KeyswitchAlarm DINT GSV If Then controller and its partner 0 Fih fall wino match or do not match ORE Or NEO OWINg e The keyswitches match e No partner is present 1 eyswitches do not mat
95. the data in the buffer If a switchover occurs the source data array tag remains unaffected 3 The CPS instruction updates array tag Since higher priority tasks cannot interrupt a CPS instruction the instruction keeps the integrity of the data Set the Task Watchdog A redundant controller requires longer watchdog times than a Times non redundant controller To avoid a major fault type 6 code 1 due to a watchdog time out after a switchover complete the following actions Estimate a Watchdog Time Set the Watchdog Time for a Task Determine the Scan Time of a Task Estimate a Watchdog Time A redundant controller requires longer watchdog times than a non redundant controller e After a switchover the secondary controller starts the scan at the beginning of the program that was in progress in the primary controller at the time of the switchover e The watchdog timer for the task that contains the program however is not reset e If the watchdog time does not include time for a complete rescan of the program a major fault could occur Publication 1756 UM523C EN P June 2003 Configure and Program the Controller 4 21 To estimate watchdog time for a task use the following formula Watchdog time 2 2 maximum scan time 100 ms where Maximum scan time is the maximum scan time for the entire task when the secondary controller is synchronized Once you enter a watchdog time use the actual scan time for a t
96. to 375 milliseconds Larger RPIs may produce a bump at switchover Q 5 Task watchdog Watchdog time gt 2 maximum scan time 100 ms 4 20 time where Maximum scan time is the maximum scan time for the entire task when the secondary controller is synchronized Publication 1756 UM523C EN P June 2003 ControlLogix Redundancy Overview 1 9 RSLogix 5000 Project Continued Parameter Criteria See page Q 6 Minimizing e A few large programs 4 10 scan time e Minimal use of SINT or INT tags e Related data in arrays and user defined data types e Boolean data in BOOL arrays e Instructions execute only when required 7 Data integrity Special treatment for 4 15 e Bit Shift Left BSL and Bit Shift Right BSR instructions e FIFO Unload FFU instructions e Logic that is scan dependant Q 8 Produced and If you want a controller in another chassis to consume a tag from the redundant controller use 4 6 consumed tags a comm format of None In the 1 0 configuration of the consuming controller select a comm format of None for the remote CNB module the CNB that is physically in the redundant chassis 9 Message For any MSG instruction from a controller in another chassis to a redundant controller cache 4 6 MSG the connection instructions Publication 1756 UM523C EN P June 2003 1 10 Controllogix Redundancy Overview Notes Publication 1756 UM523C EN P June 2003 Chapter 2 Design the System
97. uires 2 slots e Same slot assignments in each chassis m 3 Controllers 1756 L55M13 L55M14 L55M16 L55M23 or L55M24 controller 2 3 e Identical controllers for each redundant pair same catalog number series revision and memory size e Enough memory for 2 copies of all data 4 Connections Redundant controller requires 7 connections for redundancy 2 6 5 CNB modules 1756 CNB D or CNBR D module or modules 2 9 5 4 e Identical modules for each redundant pair same catalog number series and revision e CPU usage lt 75 e CNB modules have the same keeper information m 6 SRM modules 1757 SRM module 2 9 e Identical modules for each redundant pair same catalog number series and revision e only 1 in each redundant chassis e Uses 2 slots e Requires 1757 SRCx cable 1 3 10 50 and 100 meter lengths RSLogix 5000 Project Parameter Criteria See page 1 Number of Only one RSLogix 5000 project for the pair of redundant controllers The project automatically 4 1 projects crossloads to the secondary controller when the secondary controller synchronizes with the primary controller 2 Controller e 1756 L55 ControlLogix5555 controller 4 2 properties e Redundancy enabled Q 3 Task structure e Only one task at the highest priority 4 6 5 7 e f more than one task all tasks periodic 4 1 0 e Outputs that require a bumpless switchover are in the highest priority task 4 6 e Requested packet interval RPI less than or equal
98. unchecked You can send only unconnected messages to a 1757 SRM module Publication 1756 UM523C EN P June 2003 5 28 Maintain and Troubleshoot the System Table 5 3 Message to a Module Continued If you want to On this tab For this item Type or select synchronize the secondary Configuration Message Type CIP Generic co Service Code Ac Class name bf Instance name 1 Attribute name leave blank Source DINT tag with a value of 1 Num Of Elements 4 Destination leave blank Communication Path 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 SRM module set the clock of the SRM Configuration Message Type CIP Generic melal Service Code 10 Class name 8b Instance name 1 Attribute name 1 Source WallClockTime 0 where WallClockTime is a DINT 2 array that stores the CurrentValue of the WALLCLOCKTIME object Num Of Elements 8 Destination leave blank Communication Publication 1756 UM523C EN P June 2003 Path 1 slot number where slot number isthe 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 SRM module Maintain and Troubleshoot the System 5 29 EX
99. xx xx is the number of open connections that are in use by the CNB module number of unconnected buffers nUxx xx is the number of unconnected buffers that are in use by the CNB module state of the module s keeper function Kpxx xx is the state of the module s keeper function If xx is Then the keeper is Ai active network keeper with either e invalid keeper information or e keeper signature that does not match the keeper signature of the network Av active network keeper with e valid keeper information e keeper signature that defines the keeper signature of the network inactive network keeper with either e invalid keeper information or e keeper signature that does not match the keeper signature of the network inactive network keeper with valid keeper information that matches the keeper signature of the network Di e powering up with invalid keeper information or e offline with invalid keeper information Ov e powering up with valid keeper information that may or may not match the keeper signature of the network or e offline with valid keeper information that may or may not match the keeper signature of the network number of times that the bandwidth of the module was exceeded Bxnn nn is the number of times that the bandwidth of the module was exceeded bandwidth exceeded error since the module was turned off or reset You see this information only if the coun
100. y initiate a switchover During a switchover the CNB modules in the new primary chassis display a sequence of status messages Typically the modules displays the following sequence PwNS gt PwDS gt PwQg gt PwQS primary with primary with primary with primary with no secondary disqualified synchronizing synchronized secondary qualifying qualified secondary secondary Make Sure the Auto Synchronization Option Always 1 Display RSLinx software 2 From the Communications menu choose RSWho 3 Expand the network until you see the 1757 SRM module in the primary chassis Workstation Linx Gateways Ethernet AB_KTC x ControlNet n 1756 CNB D Backplane 1756 Ax x 1757 SRM 4 Right click the 1757 SRM module and choose Module Configuration 5 Set the Auto Synchronization option Always 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log Options b Choose Always to smehorinion Always x SRM Serial Number Name 6 Choose Apply Publication 1756 UM523C EN P June 2003 3 18 Install the System Initiate a Switchover 1 Click the Synchronization tab 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log Commands Disqualify Secondary Initiate Switchover Become ei
101. ynchronize the Controlletsy 4326 55 409 954 ein aus KK KK 3 10 Set the Auto Synchronization Option to Always 3 10 Synchronize the Controllers LE en ese ee ei ares 3 11 Download the Project to the Primary Controller 3 12 Schedule the Networks 3 13 Schedule a New Network 3 13 Update the Schedule of an Existing Network 3 15 Check the Keepers ere Gone arti ew KIR KRI hows ser 3 16 save the Project for Each Controller 3 16 Testthe Switchover Ne Ch RUES E 3 17 Make Sure the Auto Synchronization Option Always 3 17 Initiate a Switchover XAV de etn ae ed KK KK 3 18 Publication 1756 UM523C EN P June 2003 Table of Contents 2 Configure and Program the Controller Maintain and Troubleshoot the System Publication 1756 UM523C EN P June 2003 Make Sure the Controllers are Synchronized 3 18 Chapter 4 When to Use this Chapter hair bee eit ead 4 1 How to Use this Chapter AS a Nate ees eR eI 4 1 Configure the Project for the Controllers 4 2 Determine When to Retain Test Edits 4 2 Determine How to Reserve Memory 4 3 Configure a Controller for Redundancy 4 4 Configure Communications 644 464 se Hews ah Same ES 4 6 Conficute VO ss 4 ot ae Shane th di454 eet alee AS whee 4 6 Configure Produced Tags cir KIRR KII 4 7 Configure Message MSG Instructions 4 8 Conf
102. your local Rockwell Automation representative for States return procedure ControlNet is a trademark of ControlNet International Ltd www rockwellautomation com Corporate Headquarters Rockwell Automation 777 East Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen Bradley Products Rockwell Software Products and Global Manufacturing Solutions Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Rockwell Automation SA NV Vorstlaan Boulevard du Souverain 36 BP 3A B 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas Rockwell Automation 6040 Ponders Court Greenville SC 29615 4617 USA Tel 1 864 297 4800 Fax 1 864 281 2433 Europe Rockwell Automation Br histraRe 22 D 74834 Elztal Dallau Germany Tel 49 6261 9410 Fax 49 6261 17741 Asia Pacific Rockwell Automation 55 Newton Road 11 01 02 Revenue House Singapore 307987 Tel 65 351 6723 Fax 65 355 1733 Publication 1756 UM523C EN P June 2003 PN 957689 35 Supersedes Publication 1756 UM523B EN E November 2001 Copyright 2003 Rockwell Automation Inc All rights reserved Printed in the
103. zing after a switchover To reduce the CPU usage of a module you have these options e Change the network update time NUT of the ControlNet network Typically increase the NUT to reduce the CPU usage of a CNB module e Increase the requested packet interval RPI of your connections e Reduce the number of connections to through the CNB e Reduce the number of MSG instructions e Add another CNB module to each redundant chassis To get status information about a CNB module you have these options Use RSLinx Software Look at the Four Character Display Send a Message to the CNB Module Publication 1756 UM523C EN P June 2003 5 12 Maintain and Troubleshoot the System Use RSLinx Software 1 Start RSLinx software 2 Expand a network until you see your CNB module 3 Right click the module and choose Module Statistics 4 Click the Connection Manager tab number of connections used CPU usage Publication 1756 UM523C EN P June 2003 For information about a CNB module percent of CPU usage Display Where Maintain and Troubleshoot the System 5 13 Look at the Four Character Display On the front of the 1756 CNB D or CNBR D module the four character display shows the following information Cxx xx is the percent of CPU usage The range for the display is 00 99 number of open connections nC

ControlLogix® Redundancy System User Manual

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ControlLogix® Redundancy System User Manual