Home

1756-UM523 - Rockwell Automation

1. U 43129 Secondary Chassis ControlLogix Redundancy System Overview 17 Controller Communication Terms Term Crossload Synchronize Synchronized Disqualified Qualify Qualified 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 happens initially when the chassis synchronize and then repeatedly as the primary controller executes its logic The process that readies a secondary chassis 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 each other The SRM modules also provide the path for crossloading transferring the content of the primary controller to the secondary controller Synchronization occurs when power is applied to the secondary chassis and after a switchover is diagnosed and fixed The secondary chassis is ready to assume control if the primary chassis fails The secondary chassis is not synchronized with the primary chassis If a secondary chassis is disqualified it cannot take over control of the machine or process A secondary chassis can be manually disqualified same as synchronize Same as synchronized The 1757 SRM modules keep communication between the primary a
2. 164 Replace Local VO Tibe poea rA aa r i 164 Replace Any Aliases to Local I O Tags 166 Attributes of the Redundancy Object Series B ControlNet Bridge Modules Redundant System Restrictions Table of Contents 9 Appendix C Ti COGUCHIOM 2 4 ata wil eo uw cies eek eS We Gu ce oes eee 169 Attributes of the Redundancy Object 169 Appendix D INMOGUCHOM 4 acted ew bie ae beds edb oe a 173 Losing Communication while Bridging Via a Series B ControlNet BMS Module 43056 6a oe ewe ek eth soe beth ee oe 173 Communication Stoppage While Using a Series B ControlNet Bidee WO CIN cay ich ae Skah ae ats teed Sede ie Gay eat htiah oe fats Ae 174 Appendix E COUCU 6 44 08 4 abt ted ee ee eta aes 177 Redundant System Restrictions 0 0 000005 177 Index Rockwell Automation Support 0 0 0 0 0000000000 186 Installation Assistance x s a 0c ad deh Aon uo hae ee 186 New Product Satisfaction Return 0 186 Publication 1756 UM523F EN P December 2006 10 Table of Contents Publication 1756 UM523F EN P December 2006 Preface Purpose of this Manual This manual guides the design development and implementation of a redundancy system for a ControlLogix controller Who Should Use this This manual is intended for those in these professions who design and Manual develop applications that use ControlLogix controllers e Software engineers e Control engineers e Applicati
3. General Connection ASNetiwors Module Info Backplane Type 1756 CNBR D 1756 Control et Bridge Redundant Media Vendor Allen Bradley Name Local_CNB Node z Description Slot Revizion 5 Electronic Keping Compatible Keping C Save the project Publication 1756 UM523F EN P December 2006 Action 3 Open the SRM configuration tool for the primary chassis 4 Disquality the secondary chassis The secondary chassis is disqualified Update Modules and Redundant Systems 131 Details A Start RSLinx software B From the Communications menu choose RSWho C Open the branches of your network until you find the 1757 SRM module in the primary chassis D Right click the 1757 SRM module and choose Module Configuration Gss AB_ETH 2 Ethernet oe A 10 688 88 130 1756 ENBT A 1756 ENBT A Fl A 10 88 86 146 1756 EWEB A 1756 EWEB A B E Backplane 1756 A7 4 H A 00 1756 L63 LOGIXSS63 1756 L63 4 15 53 2 fl A oL 1756 CNB D 1756 CNB D 5 044 Build 030 oo 02 1756 EWEBIA 3 05 1757 5RM ff 10 858 68 147 1756 E _ Pemove H E AB_VBP 1 1789 4174 Vir Driver Diagnostics Configure Driver Device Properties Module Configuration A Click Configuration B Set Auto Synchronization to Never 1 5 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Statue Ewent Log System Update Options Auto Sunchronizati
4. Publication 1756 UM523F EN P December 2006 Configure and Program the Controller 83 Interrupted Switchover 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 for example the continuous task Primary Controller rd oy e This portion of the task is not executed during this scan 3 e Instructions executing at the time of the switchover do not complete in this scan Switchover occurs Secondary Controller A This 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 during 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 primary controller s last scan To prevent a scan from repeating after a switchover e look for array shift instructions e look for scan dependent logic e take preventative actions Publication 1756 UM523F EN P December 2006 84 Configure and Program the Controller Look for Array Shift Instructions These instructions might corrupt data during a switchover e BSL e BSR e F
5. The SRM configuration tool doesn t have a description for the event The clock of the SRM changed This happens when you e use the SRM configuration tool to set the clock e connect the SRM to another SRM that is already primary The SRM synchronizes its clock to that of the primary SRM Once you have reviewed your SRM event log you can export specific logged events from the SRM event log to a CSV or TXT file To export the SRM event log perform this procedure which specifically allows you to e look at the event log in spreadsheet software such as Microsoft Excel e send the event log to someone else Before You Begin The SRM configuration tool lets you export events from both the primary and the secondary chassis at the same time Event Log Time 743504 12 4 4004 16 04 27 055 7436503 12 4 4004 16 04 27 050 f4sse2 14 4 4004 16 02 26 967 43601 14 4 4004 1b 02 2691 S720 12fo 2004 14 10 435 094 9719 TAA 2004 16 02 27 052 olot flodule Description 2 1 56 EVWEB 69 Equally Able To Control oS 1 5 SRM 14 Chassis Redundancy State ch 2 1756 EVVEB 4 4 Entered Qualification Phase 4 6 175 SRhl 2E Qualification Complete 51757 5RM fC Porte Communication error 9 1757 SRhl 0E Chassis Redundancy State ch Publication 1756 UM523F EN P December 2006 116 Maintain and Troubleshoot the System Action 1 Open the SRM configuration tool for the primary chassis 2 Go to the event log IMPO
6. C Change the controller to the newer revision fo Controller Properties My_Redundant_Controller Major Faults Minor Faults Date Time Advanced SFC Execution File Redundancy Nonvolatile Memor Memory E Serial Port System Protocol User Protocol Vendor Allen Bradley Type 17 56 L63 Controllogm5563 Controller Revizion 13 25 hange Controller Example Change the controller from revision 13 to revision 15 D Change the Revision of each local communication module to match what its revision will be after you update Its firmware Example Suppose you plan to update the firmware of each CNB D module in the redundant chassis to revision 7 12 In that case open the properties for each CNB D module in the chassis and set the revision to 7 12 3 110 Configuration 239 1756 Backplane 1756 410 Pl 0 1756 CNB D Local CNB gt Controlet W Module Properties Local 0 1 56 CNB D 7 12 General Connection ASNetwors Module Info Backplane Al 1 1756 ENBT 4 Local_ ENB Type 1756 CNB 2D 1756 Control et Bridge Tr Ethernet Vendor Allen Bradley i Mame Local CNB Description mr Eee If you cannot select the new revision then change the electronic keying to either compatible keying or disable keying Electronic Keping p Publication 1756 UM523F EN P December 2006 144 Update Modules and Redundant Systems Action Details 12 Download the project to the s
7. Device Memory Help Node Name Redundant_Chassis Address Alias_T opic 1 Active Topic ie When you create tags for your HMI project use the alias topic in the address of the tag Keep a Message Going to If you are not using IP swapping any controller that sends a message the Prim ary Chassis to a redundant chassis has to point to the new primary chassis after a switchover Sending Message to Primary Chassis xX IN B el ace 7 IP Address A Pe ware oer IP Address B N LIGE SERN L JE 5 N 5 IN 5 B 5 B Chassis A Chassis B Switchover Primary ye Primary In this procedure use CIP Generic messages to determine which chassis is primary Then send a Message MSG instruction to the primary controller Publication 1756 UM523F EN P December 2006 set Up EtherNet IP Communication Across Subnets 155 MSG L JE Type CIP Generic _ C gt N oa MIT O Chassis A MSG L JE Type CIP Generic amp 5 N 5 B Chassis B To keep a Message MSG instruction going to the new primary chassis after a switchover e create a periodic trigger for the messages e obtain the redundancy state of chassis A e obtain the redundancy state of chassis B e determine which chassis is primary e send the message to the appropriate controller Create a Periodic Trigger for the Messages Free running timer that triggers the execution of MSG instructions The timer runs for 2 seconds 200
8. If you increase the system overhead time slice to 33 unscheduled communication occurs every 2 ms of continuous task time for 1 ms 1 ms 1 ms 1 ms 1 ms 1 ms 1 ms 1 ms Unscheduled Communication 2 ms 2 ms 2 ms 2 ms 2 ms 2 ms 2 ms 2 ms 2 ms Continuous Tesk E E EE HmHH HH i Enter a System Overhead Time Slice To change the system overhead time slice perform this procedure 1 Right click on your controller and select Properties Be o LL Ris A a a New Module PA Cut Ctrl p Chrl C Ctrl Delete Del Cross Reference Cbkri E Description 2 Select Advanced General Serial Fort System Rgotocal l User Protocal Major Faults Minor Faults DateTime Advanced SFC Execution File Memory Used Unused Total Controller Fault Handler none gt ag Fower Up Handler none T system Overhead y Time Slice 3 Type or select a value for the system overhead time slice 4 Click Publication 1756 UM523F EN P December 2006 122 Maintain and Troubleshoot the System Make All Your Tasks Periodic Action Details 1 If you have more than one task make If the controller contains only a periodic task or tasks the system overhead time slice value them all periodic tasks has no effect Unscheduled communication happens whenever a periodic task is not running Example Suppose your task takes 50 ms to execute and you configure its period to 80 ms
9. e No unused tags e Arrays and user defined data types instead of individual tags e User defined data types as compact as possible e Code as compact as possible e Code runs only when you need it e Data grouped by how often you need it e DINT tags instead of SINT or INT tags special treatment for e Bit Shift Left BSL and Bit Shift Right BSR instructions e FIFO Unload FFU instructions e logic that is scan dependent 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 comm format of None for the remote CNB module the CNB that is physically in the redundant chassis This comm format of None is only available over a ControlNet network For any MSG instruction from a controller in another chassis to a redundant controller cache 70 the connection Publication 1756 UM523F EN P December 2006 ControlLogix Redundancy System Overview 25 Operator Interface Terminals Parameter EtherNet IP Network e PanelView Plus terminal e VersaView industrial computer running a Windows CE operating system RSView Supervisory Edition software with RSLinx Enterprise software RSView Supervisory Edition software with RSLinx 2 x software RSView 32 software Any other HMI client software that uses RSLinx 2 x software PanelView Standard terminal PanelView 1000e 1400e terminal ControlNet
10. 1 Start RSNetWorx for ControlNet software 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 2 From the Network menu choose Keeper Status 3 4 Keeper Capable Node Valid Keeper Offline file ee 3 Make sure the list contains all your keeper capable nodes This includes the CNB modules in the secondary chassis Publication 1756 UM523F EN P December 2006 108 Maintain and Troubleshoot the System Edit Sessions in Progress secondary Chassis Action 1 Open the SRM configuration tool for the primary chassis Publication 1756 UM523F EN P December 2006 4 Make sure that each node has a valid keeper signature If the Valid Keeper column shows Then Yes The node has a valid keeper signature No select the node and choose Update Keeper 5 Choose Close To see if a computer is stopping the secondary chassis from synchronizing you must see if an edit session is in progress To edit sessions in progress perform this procedure when a secondary chassis will not synchronize and the CNB modules in the secondary chassis show CMPT Actions Details A Start RSLinx software B Fro
11. 1756 CNBR 1756 ENBT 4 3 Module ControlLogix5555 controller ControlLogix5561 controller ControlLogix5562 controller ControlLogix5563 controller ControlNet bridge module 1756 10 100 Mbps EtherNet IP Bridge Twisted Pair Media 1756 10 100 Mbps EtherNet IP Bridge w Enhanced Web Services Redundancy module Publication 1756 UM523F EN P December 2006 1756 EWEB 4 3 1757 SRM 4 3 Important Terms ina Redundant System Term Primary Controller Primary Chassis secondary Controller secondary Chassis Switchover Primary Chassis Switching from One Controller to Another ControlLogix Redundancy System Overview 15 Redundancy requires no additional programming and is transparent to any devices connected over an EtherNet IP or ControlNet network Redundancy uses 1757 SRM modules to maintain communication between the pair of redundant chassis In a redundant system these terms describe the relationship between the two redundant chassis Redundancy Terms Description The controller that is currently controlling the machine or process The chassis that contains the primary controller or controllers The controller that is standing by to take control of the machine or process A secondary controller always resides in a different chassis than the primary controller The chassis that contains the secondary controller or controllers Transfer of control from the primary controller to the secondary controller After a
12. AOJO 4 6 St ache Le hh eae ade PEERS ee 129 Change CNB Modules from Series D to Series E NICON yaara banaan wee Sars ame hae ee 129 BElore YOU BEGIN 4 sza area 4853090 be Ramee ees 129 PCWOMS es S20 his 6 tet Jaynes ee ek is oi Sakae Ot ee te 130 Update a Redundant Control System Offline 136 Update an Online Redundant System 138 Redundant System Relationships 139 Appendix A AOUE enee oe do Hine ee Eas Re Ee ee wee eee ee 147 Keep an HMI Communicating with the Primary Chassis 148 Install the ControlLogix Redundancy Alias Topic Switcher Software 4 ee eederore aa 149 Configure a Driver to Communicate with the Primary and Secondary EtherNet IP Modules 150 Create a DDE OPC Topic for Each Controller 151 Greate anm Alias TOPIC 3 27444 e6N Se a eee eee es 152 Set Up the Alias Topic Switcher 0 153 Address the Alias Topic in the HMI Project 154 Keep a Message Going to the Primary Chassis 154 Create a Periodic Trigger for the Messages 155 Get the Redundancy State of Chassis A 156 Get the Redundancy State of Chassis B 157 Determine Which Chassis is Primary 159 Send the Message to the Appropriate Controller 160 Appendix B IAOU OM 4 a acd oe 6 let irs ee OM ola eee 163 Convert Local Modules to Remote Modules 163 Reconfigure the Local I O Modules
13. Address of the module Percent of CPU usage Number of open connections Number of unconnected client buffers Number of unconnected server buffers State of the module s keeper function Number of times that the bandwidth of the module was exceeded Maintain and Troubleshoot the System 125 Four Character Display Readings Where A xx Cxx xx Is the percent of CPU usage The range for the display is 00 99 xx isthe node address of the module nCxx xx S the number of open connections that the module is using Ucxx xx isthe number of unconnected client buffers that the module is using You see this number only if the module is using 80 of its buffers or more The module stops showing the number if the number drops below 50 xx isthe number of unconnected server buffers that the module is using You see this number only if the module is using 80 of its buffers or more The module stops showing the number if the number drops below 50 Usxx Kpxx xx isthe state of the module s keeper function Then the module is Active network keeper with either e invalid keeper information or e keeper signature that does not match the keeper signature of the network V 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 signa
14. Allen Bradley ControlLogix Redundancy System Catalog Numbers 1756 CNB D E 1756 CNBR D E 1756 ENBT 1756 EWEB 1756 L55 1756 L55M12 1756 L55M13 1756 L55M14 1756 L55M16 1756 L55M22 1756 L55M23 1756 L55M24 1756 L61 1756 L62 1756 L63 1757 SRM User Manual Rockwell Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls publication SGI 1 1 available from your local Rockwell Automation sales office or online at http literature rockwellautomation com describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples a
15. Complete Module Seconda Readiness State Compatibility i lt empty ae zemptp gt a s 2 0 1756 LB3 Disqualified Primary 3 empty 4 0 17 56 CNBR Disqualified Primar 5 0 1757 SAM Disqualified Primar 5 empty T empty E 0 17 56 CNBR Disqualified Primary J 0 1756 ENBT Disqualified Primary q empty A Click Synchronization 1797 5RM REDUNDANCY MODULE Module Into Configuration Synchronization Synchronization Status Event Log System Update r Redundancy Commands Sonn sce iOnorotoneannoacosorononeosoaneeronorarsoanererononad B Click Synchronize Secondary and then Yes C Wait for the chassis to synchronize g Chassis 4 Primary with Synchronized Secondary 4uto Synchronization State Never 175 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Update Initiate Switchover ee Redundancy Commands D Click Initiate Switchover and Yes Repeat steps 6 8 for the CNB modules in the new secondary chassis Update Modules and Redundant Systems 135 Action Details 12 Synchronize the chassis A Go to the SRM configuration tool for the primary chassis B On the Configuration tab change the Auto Synchronization option to Always 1 57 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Stat
16. 14 ControlLogix Redundancy System Overview About the Main Parts of a The ControlLogix redundancy system uses an identical pair of ControlLogix chassis to keep a machine or process running if a Redundant System ki problem occurs with any hardware in one of the chassis This diagram illustrates the layout of a simple redundant setup ControlLogix Redundant System ewort sass 55588 085 SREEE ogo Network 2 ControlNet Network for EtherNet IP Network or I O Communications ControlNet Network for HMI At Least 2 Other ControlNet Nodes with Node Numbers That are Lower Than Those of the Two 1756 CNB Modules in the Redundant Chassis Identical Pair of ControlLogix Chassis that Controls a Machine or Process Computer That is Connected to the Network Access Port of a Remote Node 43128 Firmware Combinations These firmware combinations make up revisions 15 56 and 15 57 of That Make Up a Redundant the ControlLogix redundancy system System ControlLogix Redundancy Firmware Combinations Catalog Number Series Firmware Revision 1756 L55Mxx 15 57 1756 L61 15 56 1756 L62 Any 15 56 1756 L63 15 56 1756 CNB DO 7 12
17. Adjust CPU Usage for a CNB Module 123 e Store a project to the nonvolatile memory of a controller Store or Load a Project Using Nonvolatile 126 Memory To find and fix the cause of an unplanned switchover or loss of synchronization perform this procedure when e an unplanned switchover happens e a chassis that was synchronized becomes disqualified Actions e Do the 1756 CNB D E or 1756 CNBR D E modules in the primary chassis show PwQS e Yes Go to Interpret the SRM Event Log on page 109 e No Goto step 2 e Does any module in the primary chassis show PwNS e Yes Go to step 2 e No Goto step 3 1 Use this table to troubleshoot the secondary chassis And each communication And a secondary Then module in the primary communication module chassis has a secondary chassis Has a matching partner in the Red OK light A Power cycle the module B Replace the module if the Red OK light keeps coming on Green OK light Check the 1757 SRC cable for a proper connection Does not have a matching Install a matching module partner in the secondary chassis Maintain and Troubleshoot the System 105 2 Wait several minutes for the system to try to synchronize What do the CNB modules in the primary chassis show e PwOS Stop Your system is synchronized e PwDS Go to step 3 3 Use this table to troubleshoot the secondary chassis Ifthe SRM module And a secondary CNB Anda second
18. In that case the controller has 30 ms out of every 80 ms for unscheduled communication 50 ms 50 ms 50 ms 30 ms 30 ms 30 ms Unscheduled Communication 2 Follow these guidelines to set the If you have multiple tasks make sure that periods of the tasks e The execution time of a highest priority task is significantly less than its period e The total execution time of all your tasks is significantly less than the period of the lowest priority tasks This generally leaves enough time for unscheduled communication For example in this configuration of tasks e The execution time of the highest priority task Task 1 is significantly less than its period 20 ms is less than 80 ms e The total execution time of all tasks Is significantly less than the period of the lowest priority task 50 ms is less than 100 ms 3 Tune the periods of the tasks Adjust the periods of the tasks as needed to get the best trade off between executing your logic and servicing unscheduled communication 4 Look for overlaps Look at the Monitor tab of the properties of the task to see if overlaps are happening An overlap happens if the period of a task is less than its scan time If you see overlaps increase the period of the task Publication 1756 UM523F EN P December 2006 Maintain and Troubleshoot the System 123 Check the Allocation of sian a a e aaa of oe o for tags and the rest for logic Depending on how you configure t
19. addresses during a switchover 20 Publication 1756 UM523F EN P December 2006 180 Index configure 50 requirements 23 estimate program scan time 4 EtherNet IP network configure modules 50 design 21 IP swapping 20 module requirements 23 plan 38 proper use 177 event log export 115 interpret 109 EWEB module addresses during a switchover 20 configure 50 requirements 23 export event log 115 F FFU instruction 82 finalize online edits 67 firmware update 51 firmware combinations redundant system 14 G Get System Value instruction 87 GSV instruction 87 H HMI configure tags 73 optimize communication 119 1 0 placement 21 31 49 import event log 115 install rails 49 remote chassis 49 system 43 interpret SRM event log 109 Publication 1756 UM523F EN P December 2006 IP address assign 50 what happens during a switchover 20 IP swapping overview 20 K keeper signature check 99 update 107 L load project from nonvolatile memory 126 locked for update 138 locked switchover 138 message configure 72 Instruction 72 send to SAM module 91 Microsoft Excel import event log 115 minimize scan time 76 modules update 129 MSG instruction 72 NAP 16 network access port 16 nonvolatile memory load a project 126 store a project 126 0 online edits during a switchover 18 finalize 67 plan for 65 open SRM configuration tool 53 operator interface terminals placement 3
20. 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 F Workstation E Linx Gateways Ethernet F AB_KTC x ControlNet E n 1756 CNB D E E Backplane 1756 Ax ye XX 1756 module 1757 SRM 4 Right click the 1757 SRM module and select Module Configuration Flag 4B_ETH 2 Ethernet ol A 10 668 88 130 1756 ENBT A 1756 ENBT A A 10 88 86 146 1756 EWEB A 1756 EWEB A A Backplane 1756 a7 4 fl A 00 1756 L63 LOGIX5563 1756 L6g 4 13 53 2 fl Al O41 1756 CNB D 1756 CNB D 5 044 Build 030 z 02 1756 E WEBI 05 1757 5RM ff 10 886 88 147 1756 E __ Femove HE AB_VBP 1 1789 41714 Vir Driver Diagnostics Configure Driver Device Properties Module Configuration 5 Click Synchronization 1757 SRM REDUNDANCY MODULE E E jm Module Into Configuration Synchronization Synchronization Status Event Log System Update Redundancy Commands Synchronize Secondary iequality Secondary Initiate Switchover A Publication 1756 UM523F EN P December 2006 Maintain and Troubleshoot the System 119 6 Click Synchronize Secondary and then choose Yes to confirm 7 Click OK 8 In the primary chassis what do the CNB modules display PwQg Primary with Synchronizing Synchronization is in progress Qualifying Secondary e Continue waiting It may take several minutes to synchronize the s
21. 87 PCO ING tte cytes ong te Se acres hy Suet ee te Ort te reed 3 Example t Ladder Dig erat ios key a es eos Se 87 Example 2 Structured Text 0 0 00 00000 0005 87 Check Your Wonk 4065 miai di eine ee dbekeede 88 Additonal RESOUICES 2 Bee eA CA EE SHR ES EES 88 Condition Logic to Run After a Switchover 89 Example is Ladder Dig eras ce cetaa bb bees eed 89 Example 2 Structured Texts anis ep nA weed 90 Send Message to the SRM ss nb tae od ee ee a eee 91 BelOterY OU Beo a 444 oe4o4eeRc eS2ecnSbeetene 92 ACON 2 22648 5U wages eee weet eee eee eees eed 95 Download the Project to the Primary Controller 95 Schedule a ControlNet Network 0 0 000000 cee 97 Schedule a New Network 234544235444 54240 4085 97 Update the Schedule of an Existing Network 98 Check the Keepers ogy weds L EE EE ok E ew ox 99 Save the Project for Each Controller 99 Set Task Watchdog Times o an aaau deen ke ba SU dus 100 Chapter 6 Faleole seal ae a een ee eae a ee ee meee oer eee eee 103 Diagnose a Switchover or Disqualification 104 ACON 4 2 4 2 40 4 8 5 es Od OAs er ee ee oO ees 104 Troubleshoot a Failure to Synchronize 105 Update a Keeper SISnANiTe 2 4 hot awe Pee oe kaw Sey 107 Pelor VOU Deen aeea 5a 24 os do eae SG oeben eee es 107 ACHD erada FoR we Rn Bic ca tattle ia hak be Oe eee tes Ste eats 107 Bait SessiOns i Prostess 4 244 4a 60 4 hee e
22. 97 Set Task Watchdog Times 100 Plan for Online Edits Before editing online e decide if you want to keep test edits after a switchover e be aware that finalizing edits removes your original logic e decide how you want to set aside unused memory Publication 1756 UM523F EN P December 2006 66 Configure and Program the Controller Test Edits _ Publication 1756 UM523F EN P December 2006 Decide if You Want to Keep Test Edits after a Switchover When you edit logic while online with the controller the edits may fault the controller and cause a switchover Test Edits Tag 3 Tag 4 Tag 5 ea Tag 3 Tag 5 Fi R R Fi If test edits fault the primary controller they will likely also fault the secondary controller To prevent faulting any test edits are deactivated untested during a switchover As an option you can keep the edits active after a switchover Retention of Test Edits Advanced Redundancy Configuration Memory Usage Indicate whether more of the processor memory that is free after download i to be reserved for online creation of tags or logic Reserve more memory for online addition of Tags _ Logic Test Edit Options If 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
23. D Choose OK Cancel Apply Help Publication 1756 UM523F EN P December 2006 Configure and Program the Controller 101 Action Details 3 Determine the real scan time of a task Complete these steps while the controller is running E Controller Primary F Tasks E MainTask A Right click the task and choose Properties B Click Monitor lee Task Properties MainTask General Configuration Program Schedule Monitor C Look at the scan times Scan Times Elapsed Time Mar mz Heset Longest time it has taken in microseconds to scan this task Time it took in microseconds to scan this task the last time it ran D If you want to clear the Max counters and start over click Reset hir ms Taek Overlap Count SS E Choose OK Cancel Appl 4 See if the watchdog time is big enough A Calculate the smallest watchdog time for your task using the real scan time of the task smallest watchdog time 2 maximum scan time 150 ms B Is your watchdog time more than the smallest watchdog time from step 4A above e Yes Stop Your watchdog time is OK e No Repeat step 2 and enter a new watchdog time Publication 1756 UM523F EN P December 2006 102 Configure and Program the Controller Notes Publication 1756 UM523F EN P December 2006 Chapter 6 Maintain and Troubleshoot the System Introduction This chapter explains how to commission maintain
24. EN P December 2006 70 Configure and Program the Controller Configure Communications A redundant system requires some specific configuration choices for Publication 1756 UM523F EN P December 2006 successful communications Use this section to perform these redundancy tasks e Configure I O e Configure produced tags e Configure message MSG instructions e Configure tags for an HMIConfigure I O For each module in your system make sure that the requested IMPORTANT l i ane packet interval RPI 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 Configure Produced Tags IMPORTANT During a switchover the connection for tags that are consumed from a redundant controller may time out e he 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 comm format of None for the remote CNB module the CNB that is physically in the redundant chassis If
25. Media Redundancy Network Name 9 Turn on the power to each chassis Start RSNetworx for ControlNet software From the File menu choose New From the Network menu choose Online Select your ControlNet network and choose OK Select the Edits Enabled check box From the Network menu choose Properties From Network Parameters type or select these parameters Specify Repetitive time interval in which data is sent over the ControlNet network Greatest node number to use scheduled communications on the network Channels in use Name for the network Choose OK Publication 1756 UM523F EN P December 2006 98 Configure and Program the Controller Publication 1756 UM523F EN P December 2006 10 11 12 13 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 rewrite Schedule for all Connections button default and choose OK Update the Schedule of an Existing Network To update the schedule of an existing network perform this procedure 1 2 8 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 Network Parameters update
26. Message Instructions If the MSG instruction Then originates from a redundant controller During a switchover The message instructions status bits are updated asynchronously to the program scan Consequently you cannot crossload your message Instructions status bits to a secondary controller During a switchover any active message Instructions become Inactive When this occurs you will need to reinitialize the execution of your message Instructions in the new primary controller During qualification The scrolling display changes from CMPT for compatible to Ofng for qualifying e f a configured message is cached the primary controller automatically establishes a connection with no errors e f a configured message is uncached or unconnected the primary controller receives Error 1 Extended Error 301 No Buffer Memory Publication 1756 UM523F EN P December 2006 Configure and Program the Controller 73 Configured Message Instructions Continued If the message Then instruction Is targeted toa redundant controller During the erroring out All backplane communications cease This stoppage allows the redundant controller to receive the message of a message instruction required to perform a switchover or any diagnostics Important f any of your messages are active during a switchover you can expect one of these things to happen e Cached and connected messages cause the message Instruction to pause for 7 5 seconds because the init
27. P December 2006 74 Configure and Program the Controller Estimate the Crossload Time of a Program Consideration The controller crossloads data at the end of every program The crossload time depends on how much data changed In a redundant system a ControlLogix5561 5562 or 5563 controller is up to 30 faster than a ControlLogix5555 controller Publication 1756 UM523F EN P December 2006 You can estimate the crossload time of a program in a redundant controller Miele Py lowering the amount of time you spend crossloading data you can reduce your scan time Perform this procedure to gauge the time a project spends crossloading data Before You Begin Crossload Time Estimations Details The primary controller stops at the end of every program to crossload fresh data to the secondary controller This keeps the secondary controller up to date and ready to take over It also Increases the scan time when compared to a nonredundant system AS ean Time of Program _______y 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 how much data the primary controller has to crossload e The primary controller crossloads any tag to which an instruction wrote a value even the same value since the last crossload e Crossloading also requires a small amount of overhead time to tell the secondary control
28. REALs that you update every second This is better Tag Name amp Type One user defined data type for the E My Bools My Bools UOT BOOLs The controller crossloads these My Bools Bool_1 BOOL 4 bytes every scan BE y Bools Bool 2 BOUL y Bools Bool 3 BOOL One user defined data type for the DINTs My_Constants_UDT The controller crossloads these 12 bytes My Constants Constant_1 BINT only once My Constants Constant 2 DINT My Constants Cosntant 3 DINT One user defined data type for the REALs My Reals UDT The controller crossloads these 12 bytes My Fieals Real REAL every second My Rleals Real2 REAL y Reals Reald REAL Than this One user defined data type for all the My Data UOT data The controller crossloads these meaa 28 bytes every scan A Da Een S 9 Use DINT tags instead of SINT or INT tags My Data Cosntant_3 ie 4 Data Bool_ My DataBool2 aa y Data Bool 3 ez y Data Real My DaaRea2 y Data Reala To keep your logic as efficient as possible use the DINT data type instead of the SINT or INT data types A ControlLogix controller usually works with 32 bit values DINTs or REALs If you use a SINT or INT value e the controller usually changes 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 usually changes the value back to a SINT or INT value e you do not have to program the co
29. RSLogix 5000 software primary controller B Download the project to the secondary controller C When it is safe to stop the system change the primary controller to Program Mode D Turn off power to the primary chassis E Go to the 1757 SRM properties of the secondary chassis 175 SAM REDUNDANCY MODULE Properties Commands Sinehanee seconda Dizgualty secondan Intiate Switchover Become Primary Tl Choose Become Primary 6 Clear the fault of the new primary A In RSLogix 5000 software go online to the new primary controller controller CO 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 7 Upgrade the other redundant chassis Turn on power to the other redundant chassis Upgrade the required firmware of the chassis gt lo PIJ a 8 Change the Auto Synchronization Option to Always Open the SRM configuration tool for the primary chassis B On the Configuration tab change the Auto Synchronization option to Always C Choose OK Publication 1756 UM523F EN P December 2006 138 Update Modules and Redundant Systems Update an Online a o system update T of P lets age update the firmware in a secondary chassis while the primary chassis Redundant System is
30. See Configure a Controller for Redundancy on page 68 The Module Configuration window for the 1757 SRM module does not list any reasons for the failure to synchronize See Edit Sessions in Progress on page 108 DUPL NODE More than one device on No other device on the ControlNet network is set to the address of your ControlNet network is the CNB modules plus one using the same node For example if the CNB modules are set to 3 no other device should number be set to 4 e The 175 7 SRCx cable is connected to both SRM modules NET ERR The ControlNet media is e All ControlNet taps connectors and terminators are connected not completely connected Publication 1756 UM523F EN P December 2006 Update a Keeper Signature secondary Chassis 42797 Maintain and Troubleshoot the System 107 To see if the keeper signature of a CNB module is stopping the secondary chassis from synchronizing you need to update the keeper signature To update the keeper signature perform this procedure when a secondary chassis will not synchronize and its CNB modules show CPT Before You Begin The secondary chassis will not synchronize if the keeper signature of a CNB module does not match its partner This happens if you schedule the ControlNet network while the secondary chassis is off or if the CNB module was previously configured in a different network Actions
31. The size in DINTs 4 byte words secondary chassis e You must configure the controller for redundancy e You do not need a secondary chassis e To reset this value use an SSV instruction with a Source value of 0 Is there a synchronized secondary chassis e Yes This gives biggest number of DINTs that was crossloaded e No This gives biggest number of DINTs that would have been crossloaded Publication 1756 UM523F EN P December 2006 Introduction Losing Communication while Bridging Viaa Series B ControlNet Bridge Module Appendix D Series B ControlNet Bridge Modules This appendix explains the possible consequences of using a series B ControlNet Bridge module Topic Page Losing Communication while Bridging Via a Series B ControlNet Bridge Module 173 Communication Stoppage While Using a Series B ControlNet Bridge Module 174 You can temporarily lose communication with a remote chassis if you use both these modules in the remote chassis e 1756 CNB B or 1756 CNBR B module and e 1756 DHRIO module that is connected to a remote I O network Communication Loss While Bridging Redundant Chassis Pair TICN L IC S 5 IN R 5 B M Remote 0 On the first switchover after you download a project to the controller you ma IMPORTANT Tna prs youmay temporarily lose communications with these devices Publication 1756 UM523F EN P December 2006 174 series B ControlNet Bridge Modules Communication Stoppag
32. Untest the edits The Nonvolatile Memory Load Store dialog Close the Nonvolatile Memory Load Store of the controller is open dialog You tried to synchronize the chassis while Wait for the download to finish downloading a project at the same time 4 Manually synchronize the chassis Choose Synchronize Secondary and then Yes continue with synchronization 1757 5SRM REDUNDANCY MODULE Synchronize Secondary Diequalitt Secondary Initiate Switchover Become Primary Interpret the SRM Event Log To determine why a system switched over or failed to synchronize you must interpret the SRM event log To interpret the SRM event log perform this procedure when e a switchover happens but your system synchronizes again e you have already tried to use the hardware lights to find why your system will not synchronize Publication 1756 UM523F EN P December 2006 110 Maintain and Troubleshoot the System Action 1 Open the SRM configuration tool for the primary chassis 2 Go to the event log Before You Begin The SRM clock is accurate only if you e initially set it after you installed your system e reset it after any power loss to both chassis Actions Details A Start RSLinx software B From the Communications menu choose RSWho C Open the network branches until you find the 1757 SRM module in the primary chassis D Right click the SRM and choose Module Configuration Flas 4B_ETH 2 Ethernet o
33. Value Message Type CIP Generic Service Type Get Attribute Single Service Code e Class c0 Instance 1 Attribute 4 Source Element Publication 1756 UM523F EN P December 2006 set Up EtherNet IP Communication Across Subnets 157 MSG Parameter Value source Length Destination ChasA_Redundancystate Path specify the 1756 ENBT module in Chassis A Use either of these communication tab methods e Add the module to the 1 0 configuration of the controller Then use the Browse button on the Communication tab to identify the module e ype the path using port numbers and addresses Get the Redundancy State of Chassis B lf Timer_RedundancyMSGs DN 1 2 seconds are up so execute the MSG instruction again And ChasB_GetRedundState_FromENBT EN 0 The MSG instruction is not currently enabled Then Execute a MSG instruction that gets the redundancy state of Chassis B from the ENBT module in Chassis B Store the value in ChasB_RedundancyState data type DINT Timer ARedundancyMSG3 0N Chasb GetRedundState FromEN6T EN Type CIP Generic Message Control ChasB_GetRedundState_FromENBT E Timer_RedundancyMSGs Periodic trigger for the execution of MSG TIMER instructions Triggers MSGs every 2s ChasB_GetRedundState_FromENBT Message instruction that gets the redundancy state a MESSAGE of Chassis B ChasB_Redundancystate Redundancy state of the Chassis B DINT 2 PwWQS 3 PwDS 4 PwNs Publication 17
34. a rung false when you do not need to execute its Instructions e divide your logic into subroutines and call each subroutine only when needed e run noncritical code every few scans instead of every scan This is better The ADD instruction runs only when the controller gets new data New_Data on And Dest_lag crossloads only when the ADD instruction produces a new value New Data DD Add Source Tag_ je Source B Tag je Dest Dest Tag je Than this The ADD instruction writes the sum of Tag_1 Tag_2 to Dest_Tag each time the rung executes The controller crossloads Dest_lag every scan even if Tag_1 and Tag_2 stay the same DO Add Source Tag_ je Source B Tag_2 je Dest Dest Tag Publication 1756 UM523F EN P December 2006 Action Configure and Program the Controller 81 Details 8 Group your data by how often you need it 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 crossload time group your data by how often you need It Suppose that you have some DIN Ts that you use only as constants to initialize your logic You have some BOOLs that you update every scan And you have some
35. controlling outputs However during a redundancy system update remember that e the secondary chassis redundancy feature is disabled e the secondary chassis cannot act on a primary chassis failure IMPORTANT Once you have updated the firmware of the modules In the secondary chassis and downloaded the recompiled application programs to your updated secondary chassis you can then lock your redundant system and switch control to the secondary chassis without any changes to your outputs or data A locked switchover differs from a normal switchover in that only you can Initiate the former A primary chassis failure cannot initiate a locked switchover Attempting to update a system with busy 1 56 L55Mxx controllers will result in a loss of system control A system that is locked for update requires additional processor resources A CPU utilization of a synchronized pair of 1756 L55Mxx controllers that exceeds 80 suggests that adequate processor resources are not available to your application Redundant System Definitions Term Description Controlling Outputs When outputs are being controlled they are active and reacting to input state changes being monitored by your application When not being controlled outputs can still be active but cannot react to input state changes Locked for Update No application changes are allowed on either the primary or secondary controllers Your system must enter this State in order to initia
36. of faulting both controllers Configure and Program the Controller 67 Be Aware That Finalizing Edits Removes Your Original Logic Finalize all edits in program O x B MainProgram MainRoutine Hee lee alee PK id l ee ee iE MyTag_1 2 MyTag_1 1 MyT ag_ 1 0 MyT aq 1 1 j j j 4 4 MainRoutine 4 The controller removes the original logic when you finalize all edits in a program If your changes cause a major fault and a switchover the new primary controller also faults That is because there is no original logic to go back to For example the new primary controller cannot untest the edits This happens even if you set the Advanced Redundancy Configuration x controller to untest edits on a switehovet Retain Test Edits on Switchover E Memory Usage Sea Decide How You Want to Set Aside Unused Memory IMPORTANT We recommend that you leave the Memory Usage slider in the middle default position Advanced Redundancy Configuration x Retain Test Edits on Switchover 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 Reserwe more gt memory for online addition of lag Logic I 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
37. project that tries to use an EtherNet IP network for 0 produced tags or consumed tags Those communications do not work however Communication stops over an EtherNet IP network with your controllers and HMls during a switchover e You will not be able to communicate with them for up to a minute e he actual delay depends on your network topology If you need bumpless communication use a ControlNet network 2 EtherNet IP modules in same chassis does not give you redundant EtherNet IP communication A switchover still happens if one of the modules fails or a cable breaks see How an EtherNet IP Module Handles a Cable Break on page 40 To use a 1756 ENBT module in a redundant controller chassis make sure the catalog revision of the module is greater than or equal to E01 E01 E02 F01 e o find the catalog revision look at the label on the side of the module or box e f you use an older ENBT module your secondary chassis will not synchronize Guideline Decide how to handle IP addresses If you are using IP swapping give the same IP address to the primary module and its partner Design the System 39 Details If both redundant chassis areon Then Same subnet Use IP swapping Primary secondary Chassis Chassis During a switchover the primary and secondary modules swap IP addresses This lets you use the same IP address regardless of which chassis is primary see the next guideline for details D
38. s project 5 Store the new secondary controller s project 6 Synchronize the chassis f 4 Initiate a switchover Publication 1756 UM523F EN P December 2006 To store an updated project and firmware to the nonvolatile memory of a 1756 L61 1756 L62 or 1756 L63 controller while the process is running perform this procedure Use this procedure only with a 1 56 L61 1756 L62 or 1756 L63 IMPORTANT l controller Do not use the nonvolatile memory of a 1756 L55M2x controller if you have updated it to revision 15 56 If nonvolatile memory is used to store a project with a 1756 L55M2x controller use revision 15 57 or later Otherwise the controller will have an unrecoverable fault solid red OK light and clear the project from its memory Details Synchronize the chassis if they are not already synchronized A B C A Open the SRM configuration tool for the primary chassis Set the Auto Synchronization option to Never Disquality the secondary chassis Go online to the secondary controller store the project to the nonvolatile memory of the secondary controller For step by step procedures on how to store a project see Logix5000 Controllers Common Procedures publication 1756 PM001 Important Do not go back online to the secondary controller until you complete the rest of the steps in this procedure Go to the SRM configuration tool synchronize the chassis _ Initiate a switchover A G
39. switchover Typically the modules show this sequence PwNs gt PwDS gt PwOg gt PwQS primary with no primary with primary with primary with aa secondary disqualified synchronizing synchronized qualified secondary qualifying secondary secondary Actions Action Details 1 Open the SRM configuration tool for the A Start RSLinx software primary chassis B From the Communications menu choose RSWho C Open the network branches until you find the 1757 SRM module in the primary chassis D Right click the SRM and choose Module Configuration Flag 4B_ETH 2 Ethernet ol 10 686 88 130 1756 ENBT A 1756 ENBT A A 10 88 86 146 1756 EWEB A 1756 EWEB A 4 Backplane 1756 47 4 fl A 00 1756 L63 LOGIX5563 1756 L6g 4 13 53 2 fl Al 01 1756 CNB D 1756 CNB D 5 044 Build 030 5 02 1756 EWEB A 05 1757 5RM oe A 10 08 86 147 1756 E Remove HE AB VBP 1 1789 41774 Vir Driver Diagnostics Configure Driver Device Properties Module Configuration Publication 1756 UM523F EN P December 2006 60 Configure the System Redundancy Module Action 2 Start a switchover Details A Click Synchronization 1757 5RM REDUNDANCY MODULE Module Into Configuration Synchronization Synchronization Status Event Log System Update Commands SPACHIONIEE Seconda Disquality Secondary Initiate Switchover Become B Choose Initiate Switchover and then choose Yes to continue 3 Monitor the synch
40. you have already created individual tags change them to aliases for elements of an tags change them to aliases array Your logic points to the aliases The controller crossloads the base array A Create an array B Change each individual tag to an alias for an element in the array eens Bool Array B02 Bool Taq 1 Bool Array 0 Bool Array O BOOL Bool Tag 2 Bool Array 7 Bool Array 1 BOOL Bool Tag 3 Bool Array Bool Arap BOOL C Keep pointing your logic to the aa Bool Taq_1 individual tag names Bool Tag 2 Bool Array O gt Bool Arrayl J auala 5 Keep user defined data types as compact Put like data types together when you lay out a user defined data type as possible e Put all the BOOLs together e Put all the SINTs together e Put all the INTs together This is better This data type takes 12 bytes The BOOLs are together Members Data Type Size 12 byte s Name Data Type Style Description D eon BO0L Decimal Bo B00 Decima Df Boa B00 Decima C oma DN Decima D ome oN Decimi x Than this This data type takes 20 bytes The BOOLs are spread out Members Name Data Type Style Description Df Bo B00L Decimal a i R Data Type Size 20 byte s LT Publication 1756 UM523F EN P December 2006 Configure and Program the Controller 79 Action Details 6 Keep code as compact as possible Avoid checking the same conditions many times Each instructio
41. 0 ms and then resets and starts timing again Every 2 seconds Timer_RedundancyMSGs DN 1 for a single scan The MSG instructions use this bit as one of their conditions for execution Timer ARedundancyMSGs 0Dh TOM Timer On Delay Timer Timer ARedundancyM Sls Preset 000 Accum Tag Name Description Timer_RedundancyMSGs Periodic trigger for the execution of MSG instructions Triggers MSGs every 2 s Publication 1756 UM523F EN P December 2006 156 set Up EtherNet IP Communication Across Subnets Get the Redundancy State of Chassis A If Timer_RedundancyMSGs DN 1 2 seconds are up so execute the MSG instruction again And ChasA_GetRedundState_FromENBT EN 0 The MSG instruction is not currently enabled Then Execute a MSG instruction that gets the redundancy state of Chassis A from the ENBT module in Chassis A Store the value in ChasA_RedundancyState data type DINT Timer RedundancyMSGs 0N Chas4 GetRedundState FromENbT EN MSG Type CIP Generic Message Control Chast GetRedundState FromENBT HE Tag Name Description Alias For Data Type Timer_RedundancyMSGs Periodic trigger for the execution of er Mew pe instructions Triggers MSGs every 2s ChasA_GetRedundState_FromENBT Message instruction that gets the redundancy state a MESSAGE of Chassis A ChasA_Redundancystate Redundancy state of the Chassis A DINT 2 PwQOs 3 PwDS 4 PwNS MSG Parameter
42. 2 overview ControlLogix redundancy system 13 P periodic task 122 place 1 0 31 operator interface terminals 32 pair of redundant chassis 30 plan ControlNet network 35 EtherNet IP network 38 power supplies redundant 34 primary chassis 15 produced tag configure 70 program finalize online edits 67 program scan time estimate crossload time 74 minimize 76 overview 18 project download 95 edit online 18 load 126 store 126 storing while process Is running 128 proper use EtherNet IP network 177 0 qualify See synchronize rails install 49 redundancy convert existing system 163 object attributes 169 redundant system firmware combinations 14 power supplies 34 restrictions 177 update 129 update while offline 136 remote chassis install 49 remote 1 0 network design 21 restrictions redundant system 177 Index 181 revision 13 updating system 138 RIO network design 21 S scan time See program scan time task scan time schedule ControlNet network 97 secondary chassis troubleshoot 104 set SRM clock 56 task watchdog time 100 set up EtherNet IP communication 147 SRM clock set 56 SRM configuration tool check the revision 55 open 53 SRM module auto synchronization 61 configure 53 enable program control 62 export event log 115 install 46 interpret event log 109 program control 62 send message to 91 synchronize controllers 118 status of my redundancy system 87 store project to nonv
43. 56 UM523F EN P December 2006 158 set Up EtherNet IP Communication Across Subnets Publication 1756 UM523F EN P December 2006 MSG Parameter Message Type Service Type Service Code Class Instance Attribute source Element source Length Destination Path communication tab Value CIP Generic Get Attribute Single e c0 1 4 ChasB_RedundancyState Specify the 1756 ENBT module in Chassis B Use either of these methods e Add the module to the 1 0 configuration of the controller Then use the Browse button on the Communication tab to identify the module e Type the path using port numbers and addresses set Up EtherNet IP Communication Across Subnets 159 Determine Which Chassis is Primary If ChasA_Redundancystate 2 3 or 4 then ChasA_lIsPrimary 1 Chassis A is the primary chassis Chas4_lsPrimary Lik sPrimary 0 gt Limit Test CIRC Low Lirit 2 Test Chas4_ ARedundancyState High Limit 4 If ChasB_Redundancystate 2 3 or 4 then ChasB_lsPrimary 1 Chassis B is the primary chassis Chasb_ ePrimary LIM sPrimary 1 gt Limit Test CIRC Low Limit 2 Test Chasb_RedundancyState 0 High Limit 4 ChasA_Redundancystate Redundancy state of the Chassis A DINT 2 PwWQS 3 PwDS 4 PwNs ChasB_Redundancystate Redundancy state of the Chassis B DINT 2 PwQOS 3 PwDS 4 PwNS Publication 1756 UM523F EN P December 2006 160 set Up EtherN
44. 57 SRM REDUNDANCY MODULE happened around 15 40 But it is not clear mero Pecans Suse ec en just what happened DOWIE AiO ANNA ANAF WACOM Zao PACATONZaHON LAUS Psem Upod Auto Update Partner Log e The primary log shows that around that ON COFF OPEN C CLOSE time the partner SRM screamed That means it lost power Chassis B Module Description 1757 SAM 55 The partner AM has been con 1756 EWEB 40 Replied to disqualify commanc 1757 SAM 16 Chassis Redundancy State ch 1756 EWEB 30 Processing disqualification f4s405 11 30 2004 15 39 54 406 P43406 11730 2004 15 39 05 447 P4s4o 1173072004 15 35 03 417 P43406 11 30 2004 15 35 05 377 11 50 2004 15 39 09 3775 J 57 The partner AM screamed 1756 EWEB 69 Equally Able To Control 1757 SAM 1 4 Chassis Redundancy State ch 17RR F W FA fda F notered Qoualific ation Phase 4 r4ad4 4 11730 2004 15 23 02 400 P43405 1173072004 15 23 02 375 rand 11 30 2004 1 Aa Aen aa kaki Chassis 4 Module Description 5517 11 30 2004 15 41 20 050_ 5 1757 5AM 1E Chassis Redundancy State ch 5516 11 30 2004 15 40 17 0866 5 1757 5AM 40 WCT time change gt 1 secon 5515 11 30 2004 15 23 24 9114 5 1757 5AM 10 Chassis Redundancy State cF 5514 11730 2004 15 23 24 4986 1 1756 CNE 1 Transition to Not Lonely Publication 1756 UM523F EN P December 2006 Event Description Autoqualification Trigger Blank Memories Rule Chassis Modules Rule Chassis Redundancy State
45. 5AM_ 45 5YS_FAIL_L Active Failure usually means it lost its 11 30 2004 14 26 13 143 2 1756 EWEB 0 Transition to Lonely Switchover network connection 11 30 2004 11 28 26 592 2 1756 EWEB 69 Equally Able To Control State Change 11 30 2004 11 285 26 564 45 1757 5A Fl 1 4 Chassis Redundancy State changed State Change Publication 1756 UM523F EN P December 2006 112 Maintain and Troubleshoot the System Action Details 4 Double click and event for more A Double click an event to see if it gives more Information information The Extended Information Definition dialog opens B Click OK when you are done to close the Extended Information Definition dialog Example Extended Information Definition Chassis x Event Information Event Number gar Log Time 11 30 2004 a _ Event Class Skarts Stops Submitter Information Module Type 1757 5RM Slot Mo Serial Mo tin Hex z0AF29 Event Details Description t26 Module Removal Extended Data Definition ee Module removed From the chassiG See value in byte 1 of Extended Information Byte Removed modulewas Redundancy Comptant Someone removed the module for slot 2 Or the lt i module failed Extended Information Bytes fin Hex Bytel iz D Bytez Ox2 5 If the secondary log does not show the sometimes you have to use both logs to find out what happened cause look at the primary log Example e he secondary log shows that something 17
46. 756 UM523F EN P December 2006 Details 175 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Update Initiate Switchover D Redundancy Commands A Click Initiate Switchover and Yes B Wait for the system to switchover The other chassis is now the primary chassis A Chassis B Primary with Disqualified Secondary 4uto Synchronization State Never Use the ControlFLASH firmware update tool to update the modules in the new secondary chassis A Start RSLogix 5000 software and go online to the primary controller B Set the watchdog time for each task to this value or more Minimum watchdog time 2 maximum_scan_time 150 ms where Maximum scan time Is the maximum scan time for the entire task when the secondary controller is synchronized C Cancel or assemble any test edits D Remove all SFC forces from the project E Make sure that you do not need to make any changes to e O Forces Once you start this procedure you will not be able to disable or enable I O forces until you update both chassis e 0 configuration You can make those changes again when the update is done and both chassis synchronize F Save the project Action 11 Change the project revisions Update Modules and Redundant Systems 143 Details A Go offline ES gt No Edits a Bc Redundancy il B Click the Controller Properties button
47. 9 55 1756 ENBT A 1756 ENBT 4 1756 ENBTIA GP 10 88 89 56 1756 ENBT A 1756 ENBT 4 a Driver that you just added Modules in the redundant chassis Publication 1756 UM523F EN P December 2006 set Up EtherNet IP Communication Across Subnets 151 Create a DDE OPC Topic for Each Controller Not Browsing Workstation 4B6 1FF6CB4632FE ee Linx Gateways Ethernet Flas AB ETH 1 Ethernet H A 10 68 69 55 1756 ENBT A 1756 ENBT A SA 10 58 89 56 1756 ENBT A 1756 ENBT A Backplane 1756 4774 TM O02 1756 L55 4 LOGIMSS55 1756 L55 A a Al 03 1756 CNEID 1756 CNB D DOS 36 fe 04 1756 EMBT A ae Channel 0 DF1 1 Browse to the controller in Chassis A 2 Right click the controller and choose Configure New DDE OPC Topic DDE OPC Topic Configuration Project Default Topic List Data Source Data Collection Advanced Com 3 Rename the topic to indicate that this is Chassis A Topic_Chassis_A I Autobrowse 4 Click and then to update the topic Workstation 4B 1FF6CB4632FE gt Linx Gateways Ethernet gt AB ETH 1 Ethernet i 10 58 59 55 1756 ENBT 4 1756 ENBT Ei P 10 88 89 56 1756 ENBT A 1756 ENBT Backplane 1756 474 i 02 1756 L55 4 LOGIX5555 17 fl A 03 1756 CNB D 1756 CNB D C DDE OPC Topic Configuration Project Default Topic List Data Source Data Collection Advanced Com W Autobrowse Topic_Chassis_A To m i Ge Chazz 3 E 5 Create a topi
48. Chassis oo LICE S S LI GI E S DININ R DININ R 9 B B M 0 B B M T T T wo p r eS 2 42800 3 mAT The modules in each redundant chassis must match each other slot by slot e Set the rotary switches of the 1756 CNB D E or 1756 CNBR D E 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 ENBT and EWEB modules to their respective networks 3 Connect one of these fiber optic cables to the 1757 SRM modules e 1757 SRC1 e 1757 SRC3 e 1757 SRC10 e 1757 SRC50 e 1757 SRC100 Publication 1756 UM523F EN P December 2006 Install the System 49 Install the Remote Chassis You must install all I O modules and additional types of or Rails communication modules in remote chassis or on DIN rails This example shows a remote 1756 chassis You can use any type of chassis or device that you can connect to the ControlNet network l DeviceNet Network n LICIE S os ee ie S f D 5 NIN R S N N R N VO Modules N 51B B M 5 B B M B B i T 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 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
49. Chassis A Identical A Redundant Chassis B e Same Slot Number e Same Catalog Number Series and Revision e Same Memory Size controller 1756 CNB D E or 1756 CNBR D E module or modules 1 5 in each redundant chassis lt 5 total communication modules CNBs ENBTs and EWEBs in each redundant chassis Keep CPU usage lt 5 Allocate 2 consecutive node addresses for each set of partner CNB modules one in each chassis Assign each partner CNB module to the same node address Assign the higher node addresses in the system to the CNB modules in the redundant chassis 1757 SRM module e Only 1 in each redundant chassis e Uses 2 slots o Same Size of Chassis ooo 1757 SRCx cable is available in 1m 3 ft 3 m 9 ft 10 m 30 ft 50 m 150 ft and 100 m 300 ft lengths Publication 1756 UM523F EN P December 2006 30 Design the System Placement of a Pair of ears a standard o o cables a pair of an chassis primary and secondary can function up to 100 m 300 ft Redundant Chassis oe Redundant Chassis Placement Redundant Chassis A 0 Z m o Z OQ lt VM Redundancy Module Cable _ _j gt e 175 7 SRC1 cable 1 m 3 ft e 175 7 SRC3 cable 3 m 9 ft e 1757 SRC10 cable 10 m 30 ft e 1757 SRC50 cable 50 m 150 ft e 1757 SRC100 cable 100 m 300 ft Redundant Chassis B if Yo
50. Consumers i i Programmatically IOT Instruction Send Event Trigger to Consumers Simultaneous branch delays the execution of a higher priority task Tran_OOd MyCondition 1 In an SFC each path of a simultaneous branch delays the execution of a higher priority task by up to 25 us hia Step O04 E Step OOF E Publication 1756 UM523F EN P December 2006 42 Design the System Notes Publication 1756 UM523F EN P December 2006 Chapter 3 Install the System Introduction This chapter explains how to install the hardware of a ControlLogix redundancy system Topic Page Preliminary Information 43 Install the Chassis for the Controllers 45 Install Modules in the First Redundant Chassis 46 Install Modules in the Second Redundant Chassis 48 Install the Remote Chassis or Rails 49 Configure EtherNet IP Modules 50 Flash the Modules 51 Check the Installation 51 Preliminary Information Use of the Network Access Port NAP Do not connect any device to the network access port NAP of a 1756 CNB D E or 1756 CNBR D E module in a redundant chassis e f 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 1 0 devices through that CNB module If you connect a workstation to the NAP of a CNB module in
51. Ctrl H keys This dialog appears Publication 1756 UM523F EN P December 2006 Replace in Routines F Bnd eet Test Only E Eira l 4 Replace with z RERIECe f Renae til 3 Find Where all Routines e 3 e Find What Iv Wrap Direction Help F Match Whole word Only C Up Down Find Within Function Block Diagrams Ladder Diagrams Convert an Existing System to Redundancy 165 Close Find Wwiithin gt 3 Type Local 4 Type the name of the CNB module that is in the remote chassis 5 Select All Routines 6 Click Find Within gt gt Find eithin ___ amp _ _ _ lt wVoueiie um _ Function Block Diagrams Ladder Diagrams lt lt Find within Components Options Function Block Diagrams Ladder Diagrams rnstruction Wan Operand Comments Iw nstruiction Operands Instructions Iw Aung Comments Rung Types 8 42805 7 Select Ladder Diagrams 8 Check Instruction Operands 9 Choose Replace All The Search Results tab displays the changes to the logic 10 Choose Close Publication 1756 UM523F EN P December 2006 166 Convert an Existing System to Redundancy This example shows the results of replacing Local with chassis_c EXAMPLE Replacing Local with chassis_c searching through MainProgram MainRoutine Replaced Rung 0 XIC Operand 0 XIC Local 16 1 Data 0 Replaced Rung 0
52. FU 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 shifted 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 Look for Scan Dependent Logic A rung that must read the output of another rung during the same scan might miss a scan during a switchover Scan Dependent Logic CTU scan count CU Count Up U 1i Counter scan count DE Preset 1000 Accum je EGU Equal Source scan count ACE oe Source B 1000 43065 A The CTU instruction counts each scan B The EQU instruction uses the count of each scan scan_count ACC Publication 1756 UM523F EN P December 2006 Configure and Program the Controller 85 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 val
53. LEN BRADLEY DR MAYFIELD HEIGHTS OH 44124 9705 PLEASE REMOVE Rockwell Automation Support www rockwellautomation com Rockwell Automation provides technical information on the web to assist you in using our products At http support rockwellautomation com you can 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 nee
54. M module controls the synchronization and switchover of your redundancy system Use this chapter after you have installed your system to e change how the SRM supports your system e restart your system after redundant chassis regain power after a power loss Refer to this section On page Open the SRM Configuration Tool 53 Check the Revision of Your SRM Configuration Tool D5 Check the Revision of Your SRM Configuration Tool 56 Set the SRM Clock 56 Test a Switchover 59 You want to change how the SRM Change Auto Synchronization 61 Supports your system Change Program Control 62 Both redundancy chassis lost power Set the SRM Clock 56 Open the SRM Configuration Tool To configure the system redundancy module open the 1757 SRM System Redundancy Module configuration tool Complete this procedure to e set the SRM clock e test a switchover e troubleshoot a system e store or load a project using nonvolatile memory e update firmware Publication 1756 UM523F EN P December 2006 54 Configure the System Redundancy Module E Workstation E Linx Gateways Ethernet F My Network F n 1756 communication module F Backplane 1756 Ax xx 1757 SRM Publication 1756 UM523F EN P December 2006 Before You Begin RSLinx software includes and automatically installs the 1757 SRM System Redundancy Module configuration tool IMPORTANT Check your revision of the SRM configuration tool when you open i
55. MODULE Module Info Configuration Synchronization Synchronization Statue Ewent Log System Update Options Auto Synchronizatiors M Serial Number C Choose Apply and then Yes D Click Synchronization 1797 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Update Redundancy Commands Disquality Secondary Initiate Switchover E Click Disqualify Secondary and then Yes The secondary chassis is disqualified Chassis 4 Primary with Disqualified Secondary F Click OK 6 Update the SRM module in the secondary A Start the ControlFLASH firmware update tool chassis B Update the 1757 SRM module in the secondary chassis 7 Synchronize the chassis A Go to the SRM configuration tool 175 7 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Update Redundancy Commands oO EBEE Seed ease aie earn Sree ee re ees B Click Synchronize Secondary and then Yes eee ee The chassis are synchronized Chassis 4 Primary with Synchronized Secondary m Aukto Synchronization State Never Publication 1756 UM523F EN P December 2006 142 Update Modules and Redundant Systems Action 8 Initiate a switchover 9 Update the modules in the new secondary chassis 10 Prepare the RSLogix 5000 project for the update Publication 1
56. Network e PanelView Plus terminal e VersaView industrial computer running a Windows CE operating system e RSView Supervisory Edition software with RSLinx 2 x software e RSView 32 software e Any other HMI client software that uses RSLinx 2 x software PanelView Standard terminal same as a nonredundant system 28 32 38 e Use RSLinx Enterprise software revision 3 0 or later e Set aside connections for each PanelView Plus or VersaView CE terminal In this module Set aside controller 5 connections 5 connections 5 connections e Use RSLinx Enterprise software revision 3 0 or later e Use IP swapping e Keep the HMI and both redundant chassis on the same subnet Limit the number of RSLinx servers that a controller uses to 1 ideal to 3 maximum Do terminals use unscheduled 28 32 35 communication e Yes Use amp terminals per controller e No Use the number of terminals that you need e Use RSLinx Enterprise software revision 3 0 or later e Set aside connections for each PanelView Plus or VersaView CE terminal In this module Set aside Controller 5 connections 5 connections Limit the number of RSLinx servers that a controller uses to 1 ideal to 3 maximum Publication 1756 UM523F EN P December 2006 26 ControlLogix Redundancy System Overview Notes Publication 1756 UM523F EN P December 2006 Chapter 2 Design the System Introduction This chapter explains
57. 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 tags aliases for I O devices that were previously in a local chassis lf Then Yes Go to step 1 No Skip this procedure 1 From the Logic menu choose Edit Tags 2 Press the Ctrl H keys replace Publication 1756 UM523F EN P December 2006 Convert an Existing System to Redundancy 167 Replace in Tag Collections 3 ee Find What z Fara Ta eet Test Only z minele 4 Replace with Ren aGe Renae til 5 gt Find Where all Tags dd Close M wrap Direction a Help F Match Whole Word Only C Up Down Find Within Tage 3 Type Local 4 Type the name of the CNB module that is in the remote chassis 5 Select All Tags 6 Click Find Within gt gt SO lt lt lt lt lt lt O O z4 Find within T age Components Options 7 42815 7 Check Alias 8 Choose Replace All 9 Choose Close Publication 1756 UM523F EN P December 2006 168 Convert an Existing System to Redundancy No
58. On the Configuration tab change the Auto Synchronization Option to Always 1 5 5RM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Statue Ewent Log Syster Options Feral Humber C Choose Apply and Yes The chassis synchronize Chassis 4 Primary with Synchronized Secondary D Change the Date and Time in the SRM module E Choose OK Publication 1756 UM523F EN P December 2006 146 Update Modules and Redundant Systems Notes Publication 1756 UM523F EN P December 2006 Appendix A Set Up EtherNet IP Communication Across subnets Introduction This appendix explains how to keep HMIs and messages pointing to the primary chassis when IP swapping is not in use This appendix provides this information Topic Page Keep an HMI Communicating with the Primary Chassis 148 Keep a Message Going to the Primary Chassis 154 Use this appendix when e you want to use alias topics instead of IP swapping e your primary and secondary chassis are on different EtherNet IP subnets Redundant Chassis Subnets If both redundant chassis are on Then Different subnets You must point your HMIs and messages to the new primary chassis after a switchover Use this appendix to show you how Primary secondary Chassis Chassis Same subnet Stop Use IP swapping instead This lets you use the same IP address regardless of which chassis is primary Primary secondary Chassis Ch
59. 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 installing the system review these guidelines for safe handling of ControlLogix components WARNING 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 Install the System 45 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 Preventing Electrostatic Discharge This equipment is sensitive to electrostatic discharge which can cause internal damage and affect normal operation Follow these guidelines when you handle this equipment ATTENTION 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 f available use a static safe workstation e When not in use store the equipment in appropriate Static sate packaging Install the Chassis for the Controllers 1 Instal
60. RTANT When you send event logs to Rockwell Automation e send events from both the primary and secondary chassis e include all events from the latest event to the last event when you knew that the chassis were in a good state e export them in the CSV format which makes it easier to read and manipulate your data Actions Details A Start RSLinx software B From the Communications menu choose RSWho C Open the branches of your network until you find the 1757 SRM module in the primary chassis D Right click the SRM and choose Module Configuration Flag AB_ETH 2 Ethernet el A 10 686 88 130 1756 ENBT A 1756 ENBT A A 10 88 86 146 1756 EWEB A 1756 EWEB A EY Backplane 1756 a7 4 fl A 00 1756 L63 LOGIX5563 1756 L6g 4 13 53 2 fl Al O41 1756 CNB D 1756 CNB D 5 044 Build 030 02 1756 EWEB A 05 1757 5RM ff 10 858 88 147 1756 E __ Femove H AB_VBP 1 1789 41714 Vir Driver Diagnostics Configure Driver Device Properties Module Configuration Click Event Log 175 7 SKM REDUNDANCY MODULE jess I x Module Info Configuration Synchronization Synchronization Status Event Log Auto Update Meee C OFF Monnnnnnn Partner Log S Ace Export Selector Module Classification ie 1173072004 09 36 27 929 2 1756 EWEB 69 Equally Able To Control State Changes mmm Ja OAM A ad A ee Publication 1756 UM523F EN P December 2006 Maintain and Troubleshoot the Sys
61. The SRM logs only significant events It does not log events while your system is running normally C Use the slot and module columns to find the module that caused the event D Go to Interpret SRM events on page 113 to interpret the description Example Auto Update Partner Log ON C OFF OPEN CLOSE e Chassis B Description _ Classification 743355 11 30 200414 27 19 208 2 9 1756 EWEB 69 Equally Able To Control State Change Taag 1173072004 14 27 18 1956 5 1757 5A Fl 1 4 Chassis Redundancy State changed State Change 43355 1173072004 14 27 18 1295 2 1756 EWEB 44 Entered Qualification Phase 4 State Change 743352 11 30 2004 14 2718 amp 066 5 17575AM_ 2E Qualification Complete Qualification T4335 11 30 2004 14 27 18 0493 2 1756 EWEB 46 Entered Qualification Phase 3 State Charge Here is a substantial change 743350 11 30 2004 14 27 17 045 2 1756 EWEB 3E Entered Qualification Phase 2 State Change in the log time Passa 11 30 2004 14 27 15 565 2 1756 EWEB 39 Entered Qualification Phase 1 State Change Fae 1130200414271554 5 PAP SAM 20 Qualification Attemnted Gualifinatinn The slot module and Chassis A description columns show i Description Classification that the 1756 EWEB module 5456 11 30 2004 14 26 13 2376 5 1757 SRM 2B Module Removal Starts Stops in slot 2 went lonely That 5455 11 30 2004 14 26 13 1468 5 1757 5AM 30 Switchover Attempted Switchover 5454 11 30 2004 14 26 13145 5 1757
62. Through a Series B ControlNet Bridge the chassis Module e 1756 CNB B or 1756 CNBR B module e 1756 DHRIO module that is connected to a remote 1 0 network Redundant Chassis Pair Remote 0 IMPORTANT On the first switchover after you download a project to the controller you may temporarily lose communications with these devices The loss of communication occurs on the first switchover after you download the project to the redundant controller e You lose communication with the remote chassis and any devices to which you were bridging via the chassis such as the remote O modules e During the communication loss the 1 0 modules go to their configured state for a communication fault e The communication loss is temporary Communications restore themselves To prevent this situation use 1756 CNB D E or 1756 CNBR D E modules al Publication 1756 UM523F EN P December 2006 176 series B ControlNet Bridge Modules Restriction Description If the lowest node is a 1756 CNB B or If the lowest node on a ControlNet network is a 1756 CNB B or 1756 CNBR B module all CNBR B module removing a tap or communications over the network could stop if a tap to the 1756 CNB or CNBR D module is breaking a cable could stop all disconnected or breaks and then is replaced while power is still applied to the the 1756 CNB B or communications over the network CNBR D module If a tap to a 1756 CNB B or CNBR B module becomes disco
63. Time Status Cause 17171997 O0 06 54652 Locked System locked at 1 7 199 00 06 54 652 Tor attempted Publication 1756 UM523F EN P December 2006 Update Modules and Redundant Systems 145 Action Details 14 Initiate a Locked Switchover 1757 SRM REDUNDANCY MODULE Sas Module Info Configuration Synchronization Synchronization Status EventLog System Update System Update Commands kre Abort System Lock Initiate Locked Switchover in er A Click Initiate Locked Switchover and Yes B Wait for the system to switchover A locked switchover takes about as long as a normal switchover Locked Switchover Attempts Switchover Initiation Time Status Cause orfee 1 9oF 19 23 10 3367 Success Locked switchover completed at H 1 21171997 2319 04 rU SUCCESS Locked switchover completed at 271 H 2 31712719956 23 10 06 0070 Success Locked switchover completed at 31 H 3 Locked Switchover History 31717271971 23 00 00 0000 Not attempted The other chassis is now the primary chassis Chassis 4 Primary with Disqualified Secondary 4uto Synchronization State Never 15 Update the other redundant chassis Use the ControlFLASH firmware update tool to update the rest of the modules in the new secondary chassis You have already updated the SRM module in this chassis 16 Synchronize the chassis A Go to the SRM configuration tool for the primary chassis B
64. You Begin This procedure is easier to complete if you first update the firmware of your 1756 CNB D or 1756 CNBR D module s Publication 1756 UM523F EN P December 2006 130 Update Modules and Redundant Systems Firmware Update E Ifthe CNB modules are Andya Then Revision 11 1 or later 0 to Actions and start the procedure You do not need to update the firmware of the modules Not revision 11 1 or later Have a nonredundant 1 Add the revision 11 EDS files for the CNB modules if you have not chassis with an open slot already done so 2 Put one of the CNB modules into the open slot of the nonredundant chassis 3 Use ControlFlash software and update the firmware of the CNB module 4 Remove the CNB module 5 Repeat steps 1 4 for the rest of the CNB modules 6 Go to Actions and start the procedure Do not have anonredundant Go to Actions and start the procedure You will have to use the secondary chassis with an open slot chassis to update the modules i Actions g Action Details 1 Add the latest EDS files Add the revision 11 EDS files for the 1756 CNB and 1756 CNBR modules if you have not l already done so 2 Prepare the RSLogix 5000 project A Start the RSLogix 5000 software and go online with the primary controller B For each CNB D E or CNBR D E module in the local chassis set the electronic keying to compatible keying or disable keying and apply the changes W Module Properties Local 4 1 56 CNBR D 5 1
65. 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 UM523F EN P December 2006 44 Install the System Install this component 1756 A4 A7 A10 A13 or A17 chassis 1756 PA72 or PB72 power supply 1756 PA75 or PB75 power supply ControlLogix controller 1756 CNB D E or CNBR D E module 1756 ENBT module 1756 EWEB module 1757 SRM module Publication 1756 UM523F EN P December 2006 This chapter provides the sequence of tasks and the critical actions for the successful installation of a ControlLogix redundancy system It does not replace the installation instructions for the components of the system During installation refer to these publications Installation Publications According to this publication ControlLogix Chassis Installation Instructions publication 1756 IN080 ControlLogix Power Supplies Installation Instructions publication 1756 5 67 ControlLogix Power Supplies Installation Instructions publication 1756 5 78 ControlLogix Controller and Memory Board Installation Instructions publication 1756 IN101 ControlLogix ControlNet Bridge Installation Instructions publication 1756 IN5 1 ControlLogix EtherNet IP Bridge Module Installation Instructions publication 1756 INO19 EtherNet IP Web Server Module Installation Instructions publication 1756 IN588
66. after the failure of a ControlNet tap of a primary chassis 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 1756 DHRIO 1756 MVI 1756 DNB Publication 1756 UM523F EN P December 2006 50 Install the System Configure EtherNet IP Modules Action Before you begin Configure the EtherNet IP modules in the first chassis Configure the EtherNet IP modules in the second chassis Publication 1756 UM523F EN P December 2006 To use an EtherNet IP module give it an IP address subnet mask and gateway address Details A Perform these steps if you have not already e installed and connected both 1757 SRM modules e obtained the IP address subnet mask and gateway address for each EtherNet IP module See Plan the EtherNet IP Networks on page 12 e Do you know how to configure an EtherNet IP module in a nonredundant system e lf no then continue with step B e f yes then go to step B B Get this publication EtherNet IP Modules in Logix5000 Control Systems publication ENET UM001 You will use that publication when you configure each module A Turn on the power to only one of the redundant cha
67. ags This reduces the size of the tag database A smaller database takes less time to crossload To delete unused tags A Open one of the tags folders B Click Edit Tags C From the Show list select Unused Controller Tags My_Project controller _ o x Nirone My_Project contralle Show Unused F Sot TagN _ PNegName Type Description 4 a ee Y afe Monitor Tags Edit Tags 4 H D From the Edit menu choose Select All E Press the Delete key 3 Use arrays and user defined data types When you create a tag the controller always sets aside at least 4 bytes 32 bits of instead of individual tags memory The controller does this even if the tag needs only 1 bit When you create an array or a user defined data type the controller packs smaller data types into 4 byte 32 bit words This means the controller has less data to crossload This array of 32 BOOLs takes only 4 bytes E Bool Array ee ec The controller crossloads only 4 bytes These 3 BOOL tags take 12 bytes total 3 tags x 4 bytes tag 12 bytes Tipe Bool Taq_1 Bool Tag 2 Bool Tag 3 The controller crossloads all 12 bytes Arrays and user defined data types help you the most with BOOL tags But also use them for your SINT INT DINT REAL COUNTER and TIMER tags Publication 1756 UM523F EN P December 2006 78 Configure and Program the Controller Action Details 4 f you have already created individual If
68. and troubleshoot your redundancy system Simultaneous power of redundant Under this combination of conditions all must apply duplicate IP addresses on your EtherNet IP chassis pair may bump another network will cause you to lose communication with a redundant chassis pair over that EtherNet IP redundant chassis pair off the network EtherNet IP network e You have multiple pairs of redundant chassis on the same EtherNet IP network For example pair 1 and pair 2 e The IP addresses of one pair of redundant chassis is the same as another pair of redundant chassis For example pair 1 10 10 10 10 and pair 2 10 10 10 10 e A redundant chassis pair with the conflict both chassis that make up the pair simultaneously powers up For example both chassis of pair 2 power up at the same time When this occurs the newly powered up chassis use the IP address The redundant chassis pair that was previously communicating at that IP address stops communicating on the network For example when pair 2 powers up at 10 10 10 10 pair 1 stops communicating on the network e Find the cause of an unplanned switchover Diagnose a Switchover or 104 e Find why secondary chassis became disqualified Disqualification Find why the secondary controller fails to synchronize Troubleshoot a Failure to Synchronize 105 See if the keeper signature of a CNB module is stopping the Update a Keeper Signature 107 secondary chassis from synchronizing See if a computer is st
69. ary chassis secondary chassis Several switches Several subnets won t switchover or disqualify the won t switchover secondary chassis will synchronize will synchronize HMI won t be able to communicate with this chassis if it becomes primary Subnet B HMI can t communicate with primary chassis Subnet A will switchover will disqualify won t synchronize switch switch won t synchronize EtherNet IP module EtherNet IP module shows Link lost shows Link lost primary chassis secondary chassis Publication 1756 UM523F EN P December 2006 Design the System 41 Additional Design Keep these things in mind as you design your system Considerations Additional Design Considerations Switchover always triggers an event A switchover triggers an event task under this combination of circumstances task in a remote nonredundant controller e The event task is in a nonredundant controller An event task is not permitted in a redundant controller e A redundant controller triggers the event task via a produced tag This occurs regardless of how you configure the produced tag fa Tag Properties MyProducedTag General Connection HM asinum Consumers il Both configurations always trigger an Programmatically OT Instruction Send Event Trigger to Consumers event task during a switchover fe Tag Properties MyProducedTag General Connection Masinurn
70. ary controller Then has a module has a Green OK LED Does not show NET ERR Flashing Red OK light Clear the major fault of the controller Indicator It is possible that you have to clear the fault on both the primary and secondary controllers solid Red OK light A Cycle the power to the chassis B If the OK light remains solid red replace the controller and flash the controller with the appropriate revision of firmware solid Green OK light Go to step 4 shows NET ERR Check all ControlNet taps connectors and terminators for proper connections Red OK LED Indicator A Cycle the power to the chassis B If the OK light of the SRM module remains solid red contact your local distributor or Rockwell Automation representative 4 Wait several minutes for the system to try to synchronize Do the CNB modules in the primary chassis show PwQS e Yes Stop Your system is synchronized e No Go to Troubleshoot a Failure to Synchronize on page 105 Troubleshoot a Failure to To troubleshoot a failure to synchronize perform this procedure Synchronize CS IMPORTANT im If the steps in this section do not correct the situation check the usage of the CNB modules See Adjust CPU Usage for a CNB Module on page 123 If the chassis still doesn t synchronize try to manually synchronize it see Manually Synchronize the Chassis on page 118 Publication 1756 UM523F EN P December 2006 106 Maintain and Troubl
71. assis When primary and secondary chassis are on different EtherNet IP subnets they keep their IP addresses during a switchover This means that your and other controllers must be able to switch between the IP address of each redundant chassis see Chapter 2 Publication 1756 UM523F EN P December 2006 148 set Up EtherNet IP Communication Across Subnets Keep an HMI Communicating with the Primary Chassis XXXX XX i If you are not using IP swapping your HMIs must direct their communication to the new primary chassis after a switchover ControlLogix Redundancy Alias Topic Switcher software can most easily do this Look for this software on the CD along with your firmware eA 0 use the ControlLogix Redundancy Alias Topic Switcher software your computer needs an activation file for RSLinx software The activation file lets you perform DDE OPC communication The ControlLogix Redundancy Alias Topic Switcher software works with RSLinx alias topics Together they keep your HMI communicating with the primary controller after a switchover HMI Communication HMI tags In your HMI project each tag references an alias topic in RSLinx software This lets RSLinx software redirect communications to the appropriate chassis Alias topic In RSLinx software an alias topic nnn represents a flexible communication path to one of several controllers topics RSLinx Software A SS Top
72. ate changed State Changes Aili AA aiit 15 45 13 Te fo SAW 10 Chassis Redundancy State changed State Changes 5716 q2r2r 2004 15 44 34 4385 1 1756 CNB 11 Transition to Mot Lonely State Changes 4 Export your selection A Click Export Selection O x 175 7 SKEM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log Auto Update Partner Log ON C OFF ile OPEN CLOSE Export Selection Chassis B Module Description Classification Tanad qarar 2004 16 02 27 0055 2 1756 EWEB 69 Equally 4ble To Control State Changes P4353 1224 2004 16 02 27 050 z 1757 5A bl 1 4 Chassis Redundancy State changed State Changes TAJR 1279 fone 16 712 26 96 T 17RF Fw FF iSl Patered Lhialtirahan Phase A Crake hannes x File name Browse B Click Browse and choose a location and name for File Type the export file Lace C Choose CSV Comma Separated Value CSV Comma Separated value D Check the Include Extended Information check box I Include Extended Information Cancel E Click Export Publication 1756 UM523F EN P December 2006 118 Maintain and Troubleshoot the System Manually Synchronize the After a switchover you may have to manually synchronize the chassis Chassis because either e the Auto Synchronization option is not set to Always or e the chassis failed to synchronize To manually synchronize the chassis perform this procedure
73. c for the controller in Chassis B Workstation 4B 1FF6CB4632FE r Linx Gateways Ethernet ao 4B ETH 1 Ethernet Elf 10 68 69 55 1756 ENBT A 1756 ENB1 Publication 1756 UM523F EN P December 2006 152 set Up EtherNet IP Communication Across Subnets Create an Alias Topic _ In RoLinx software choose DDE OPL gt Alias Topic Configuration File Edit View Communications Station DDEfOPC Security Window Help 2 Sla Biz kzl Type a name for the alias topic that will communicate with this pair of redundant controllers NO Configure Alias Topics List of Alias Topics Alias Configuration Alias Name jalias_T opic_ 1 Available Topics 42573 AFO2 01 Change UCBs oO Add the topic for each redundant controller to the Aliased Topics list Aliased Topics Topic Chassis 4 Topic_Chazsis_B To add a topic select the topic and choose Chassis _A Add gt Chazsis_B 2UMETr r lt Remove 4 Check the Switch on command check box Uncheck the remaining check boxes Boa I Switch when bit is W Switch on command ft Zero t One This lets the ControlLogix Redundancy Alias Topic Switcher software control which topic the alias topic uses for communication 5 Click and then Close Update all Topics Publication 1756 UM523F EN P December 2006 set Up EtherNet IP Communication Across Subnets 153 Set Up the Alias Topic Switcher IMPORTANT If you s
74. cation 1756 UM523F EN P December 2006 Configure the System Redundancy Module 57 Before You Begin The SRM clock records when significant events occur Please note these characteristics of the SRM clock e Only the primary SRM s clock requires setting The secondary SRM s clock synchronizes itself to the primary SRM s clock e The SRM has no battery to keep its clock running The clock stops without SRM power e With power the primary SRM synchronizes its clock to the most recent event in its event log e The secondary SRM event log records when the secondary SRM powered up Look for WCT time change gt 1 second event e An SRM with a firmware revision 3 37 or earlier does not log its power down time If only one of the chassis powers down use the event log of the other chassis to see when it happened Look for The Partner RM Screamed event See Interpret the SRM Event Log on page 109 Actions Action Details 1 Open the SRM configuration tool forthe A Start RSLinx software primary chassis B From the Communications menu choose RSWho C Open the network branches until you find the 1757 SRM module in the primary chassis D Right click the SRM and choose Module Configuration Flas AB_ETH 2 Ethernet el A 10 686 88 130 1756 ENBT A 1756 ENBT A A 10 88 86 146 1756 EWEB A 1756 EWEB A A Backplane 1756 a7 4 fl A 00 1756 L63 LOGIX5563 1756 L6g 4 13 53 2 fl Al 01 1756 CNB D 1756 CNB D 5 044 Bu
75. changed to Crossloading Error Disqualified Secondaries Rule Failed Modules Rule Firmware Error Improper Mode or Keyswitch Position Incompatible Application Invalid Application Module Insertion Module Rejected Lock for Update Command from SRM Interpret SRM events Maintain and Troubleshoot the System 113 Use this table to interpret events recorded in the SRM s event log SRM Event Descriptions Meaning something happened that caused the system to try and synchronize again Double click the event to see what happened A check to choose a primary chassis if both chassis power up at the same time Suppose that the controllers in one chassis don t have projects while the controllers in the other chassis do have projects In that case the other chassis becomes primary A check to choose a primary chassis if both chassis power up at the same time Suppose that one chassis has more modules than the other chassis In that case the chassis with the most modules gets the first chance to become primary It becomes primary as long as the other chassis isn t more able to control the system The chassis changed to a different redundancy state e PwOS Primary with qualified synchronized secondary partner OSwP Qualified synchronized secondary with primary partner DSwP Disqualified secondary with primary partner DSwNP Disqualified secondary with no partner PwDS Primary with disqualified seconda
76. chassis that runs the code Store the ID in Chassis_ID_Now Chassis_ID_Now DINT GSV REDUNDANCY PhysicalChassisID Chassis ID Now If this is the first scan Then set the last value of the chassis ID the ID of this chassis Chassis_ID_Last DINT TE eo een Chassis ID bast 7 Chassis ID Now Enda If If the chassis ID changes a switchover happened If a switchover happens then Turn on the Switchover_Happened bit Set the last value of the chassis ID the ID of this chassis Switchover_Happened BOOL Send a Message to the SRM Configure and Program the Controller 91 Lt Chassis ID Now lt gt Chassis ID last then pWitChover Happened i 1 Chassis ID bast Chassis LD Now End If If Switchover_Happened on Then Execute the instructions that you want to execute after a switchover Turn off the Switchover_Happened bit If Switchover Happened then Put your statements here OWiEChover Happened is 0 End If You can let your logic initiate actions in the SRM Perform this procedure to e Initiate a switchover e disqualify the secondary controller e synchronize the secondary controller e set the clock of the SRM module Publication 1756 UM523F EN P December 2006 92 Configure and Program the Controller Before You Begin Before sending a message to an SRM make sure that e the SRM is configured for program control 1757 5RM REDUNDANCY MODULE Module Info Config
77. ct to the same node number to the same node number Publication 1756 UM523F EN P December 2006 20 ControlLogix Redundancy System Overview EtherNet IP Network Set both EtherNet IP modules to the SAME IP address Port Configuration Port Configuration secondary Chassis Primary Chassis 10 10 10 10 10 10 10 11 An EtherNet IP module in the secondary chassis uses the IP address An EtherNet IP module in the primary chassis uses the IP address to which it is set to which it is set 1 in the last address segment Switchover EtherNet IP Modules secondary Primary Chassis Chassis 10 10 10 11 10 10 10 10 Publication 1756 UM523F EN P December 2006 ControlLogix Redundancy System Overview 21 Quick Start Checklists These checklists provide a summary of the criteria for a successful ControlLogix redundancy system See the remaining chapters for more information on each parameter System Layout Parameter Page ControlNet Networks e ControlNet networks are the primary networks for the system 28 31 e OK to bridge to devices on other networks such as DeviceNet Universal Remote 1 0 and DH networks e Networks follow the guidelines in Logix5000 Controllers Design Considerations publication 1756 RM094 I O Placement e All 1 0 modules in remote chassis or DIN rails no 1 0 in the local chassis 28 31 e All O in only these locations e Same ControlNet network as the redundant controllers
78. cy and redundancy during an update This term in normal redundancy Equates to this term during the updating of a redundant system synchronize Lock for Update synchronizing Locking for Update synchronized Locked for Update Switchover Locked Switchover Complete this procedure to update the firmware of a redundant chassis without shutting down the process IMPORTANT Use this procedure only if your system is already at revision 13 Do not use this procedure if e your system is at revision 11 or earlier e your system Is not operating yet During this procedure you will not be able to use RSLogix 5000 software to change the mode of the controller Use the keyswitch on the front of the controller to change its mode Leave RSNetWorx for ControlNet software closed or offline throughout this procedure Otherwise you will see errors in the RSNetWorx software during the update process During this procedure e do not make any changes to the RSLogix 5000 project other than the ones called out in this procedure e make sure no one else makes changes to the project Publication 1756 UM523F EN P December 2006 140 Update Modules and Redundant Systems g Action 1 Update the software f 2 Add the latest EDS files l 3 Put the keyswitches in the REM position 4 Open the SRM configuration tool for the primary chassis Publication 1756 UM523F EN P December 2006 Details A Go to the tool tray of your computer and shu
79. dant system e PanelView Plus terminal e Use RSLinx Enterprise software revision 3 0 or later e VersaView industrial computer running a Windows CE operating system Set aside connections for each PanelView Plus or VersaView CE terminal In this module Set aside Controller 5 connections CNB 5 connections ENBT 5 connections EWEB 5 connections RSView Supervisory Edition software with RSLinx Use RSLinx Enterprise software revision 3 0 or Enterprise software later Use IP swapping Keep the HMI and both redundant chassis on the same subnet RSView Supervisory Edition software with Limit the number of RSLinx servers that a controller RSLinx 2 x software uses to 1 ideal to 3 maximum e RSView 32 software e Any other HMI client software that uses RSLinx 2 x software ControlNet network PanelView Standard terminal Do your terminals use unscheduled communication PanelView 1000e 1400e terminal anelView 1000e 1400e termina e Yes Use lt A terminals per controller e No Use the number of terminals that you need PanelView Plus terminal Set aside connections for each PanelView Plus or e VersaView industrial computer running a VersaView CE terminal Windows CE operating system In this module Set aside Controller 5 connections CNB 5 connections e RSView Supervisory Edition software Limit the number of RSLinx servers that a controller e RSView 32 software uses to 1 ideal to 3 maximum e Any other HMI client
80. disabling the controller functions originally specified under the Advanced tab of Controller Properties 4 Browse to the controller in the primary chassis A Open a branch in one of these ways F Workstation e Double click it E Linx Gateways Ethernet a My Network e Click its sign HI Sy F N 1756 communication module e Select it and press the key F Backplane 1756 Ax B Find the primary chassis Its communication module uses the address that you gave it C Find the controller ye Xx 1756 controller 5 Select the controller and choose Download The Download diaglog opens 6 Choose Download Publication 1756 UM523F EN P December 2006 Schedule a ControlNet Network In this box Configure and Program the Controller 97 Before you schedule a ControlNet network turn on the power IMPORTANT i 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 To schedule a ControlNet network e schedule a new network e update the schedule of an existing network e check the keepers e save the project for each controller Schedule a New Network To schedule a new network perform this procedure 1 2 Network Update Time Max Scheduled Address Max Unscheduled Address Greatest node number that you will use on the network
81. dits Eedundaney Does General display the controller type e If no go to step 3 e If yes go to step 6 3 Click the Change Type button 4 Select your controller 5 Click OK 6 Select Redundancy Publication 1756 UM523F EN P December 2006 Configure and Program the Controller 69 General Serial Fort System Frotocol User Protocal Major Faults l Minor Faults DateTime Advanced File Redundancy 7 Redundancy Enabled e 7 Select Redundancy Enabled General Serial Port System Protocol User Frotocol Maior Faults Minor Faults Date Time Advanced File Redundancy i Redundancy Enanled 8 Click Advanced Advanced Redundancy Configuration Memory Usage Indicate whether more of the processor memory that is free after download i to be reserved for online creation of tags or logic Reserve more memory for online addition of Tage Logic l Cancel Help e We recommend that you not check this box Leaving it unchecked prevents an incorrect online edit from faulting both the primary and secondary controller e If you want any test edits to remain active during a switchover then check this box However by doing so you run the risk of faulting both controllers e We recommend that you leave the Memory Usage slider in the middle the default position 9 Click OK 10 To close the Controller Properties dialog box dc iia Publication 1756 UM523F
82. ds 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 your local Rockwell Automation representative for States return procedure Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 1756 UM523F EN P December 2006 Supersedes Publication 1756 UM523E EN P May 2005 PN 953030 15 Copyright 2006 Rockwell Automation Inc All rights reserved Printed in the U S A
83. e While Using a Series B ControlNet Bridge Module Publication 1756 UM523F EN P December 2006 The loss of communication happens on the first switchover after you download the project to the redundant controller e You lose communication with the remote chassis and any devices to which you were bridging via the chassis such as the remote I O modules e During the communication loss the I O modules go to their configured state for a communication fault e The communication loss is temporary Communications restore themselves To prevent this situation use series D or series E ControlNet Bridge modules All communication on a ControlNet network could stop if the lowest node is a 1756 CNB B or 1756 CNBR B module This happens if you unplug or break the tap of the module while it is turned on Module Corrective Action if Then Tap of a series B ControlNet Bridge module 1 Turn off the power to the module becomes unplugged or broken 2 Replace the tap 3 Turn on the power to the module Communication on the network stops Cycle power to each primary controller on because of an unplugged or broken tap the network To prevent this situation use series D or series E ControlNet Bridge modules Restriction Communication Loss When Bridging series B ControlNet Bridge Modules 175 Loss of Communication Description You could temporarily lose communication with a remote chassis If you use both these modules in
84. e modules 3 and 4 have a primary node number of 2 If you allocate nodes 3 and 4 for the redundant chassis set both CNB modules to node 3 Nodes 3 and 4 This is only an example You can install the 2A module in any slot ee C N B SS Se ee ee pd 3 P Publication 1756 UM523F EN P December 2006 Install the System 47 2 Install a 1756 CNB D E or 1756 CNBR D E module See ControlLogix ControlNet Bridge Installation Instructions publication 1756 IN571 WARNING If you connect or disconnect the communications 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 This is only an example You can install the 4 5 6 l l modules in any slot 42799 4 Install the controller or controllers See ControlLogix Controller and Memory Board Installation Instructions publication 1756 IN101 5 Install the 1756 ENBT or 1756 EWEB module or modules 2 maximum if required Connect each module to an ethernet switch 6 Install the 1757 SRM module See ProcessLogix ControlLogix System Redundancy Module Installation Instructions publication 1757 INO92 Publication 1756 UM523F EN P December 2006 48 Install the System Install Modules in the Second Redundant
85. e chassis If you give the lowest address to a CNB module in the redundant chassis pair e ona switchover you may temporarily lose communication with 1 0 modules produced tags and consumed tags e f 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 f every ControlNet node powers down at the same time for example a plant wide power loss you may have to cycle the power to the primary chassis to restore communication Publication 1756 UM523F EN P December 2006 36 Design the System Guideline set aside 2 consecutive ControlNet addresses for each pair of redundant chassis for example nodes 3 and 4 Details e f each redundant chassis has multiple CNB modules set aside 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 Pair of CNB modules one ineach Slot and node numbers redundant chassis 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 Know that the switchover time depends on the NUT of the ControlNet network lf Primary node Secondary node primary node 1 Use
86. eb Server Module Release Notes 1756 RN604 EtherNet IP Web Server Module Installation Instructions 1756 IN588 EtherNet IP Web Server Module User Manual ENET UM527 1756 Lo5 ControlLogix Controller and Memory Board Installation Instructions 1756 IN101 1756 L61 1756 L62 1756 L63 1756 M12 1756 M13 1756 M14 1756 M16 1756 M22 1756 M23 1756 M24 1757 SRM B ProcessLogix ControlLogix System Redundancy Module Installation 1757 INO092 Instructions ControlLogix Controller and Memory Board Installation Instructions 1756 IN101 To view or download these publications go to http literature rockwellautomation com To obtain a hard copy contact your Rockwell Automation distributor or sales representative Publication 1756 UM523F EN P December 2006 Chapter 1 ControlLogix Redundancy System Overview Introduction This chapter provides an overview of the ControlLogix redundancy system including commonly used terms It also answers some common questions about a ControlLogix redundancy system Topic Page About the Main Parts of a Redundant System 14 Firmware Combinations That Make Up a Redundant System 14 Primary Chassis 15 Switching from One Controller to Another 15 Network Access Port 16 Bump in Outputs During a Switchover 16 Keep the Second Controller Up to Date 16 Making Online Edits 18 Increasing Scan Time 18 Network Addresses During a Switchover 18 Quick Start Checklists 21 Publication 1756 UM523F EN P December 2006
87. eck the Revision of Your SRM Configuration Tool on page 55 Check the revision of your SRM configuration tool to make sure that you are using the right revision of the SRM configuration tool for your ControlLogix redundancy system IMPORTANT Make sure that you check the revision of your SRM configuration tool e Revision 2 6 is compatible only with revision 13 x or later ControlLogix redundancy systems e You will cause the 175 7 SRM module to fault if you use revision 2 6 of the tool with an revision 11 x or earlier redundancy systems Perform this procedure to e use the SRM configuration tool for the first time e connect to a different ControlLogix redundancy system for the first time e update the firmware of a ControlLogix redundancy system Before You Begin RSLinx software automatically installs the SRM configuration tool Use this table to see which revision of the tool that you get RSLinx Software Versions Software RSLinx software version 2 42 RSLinx software version 2 43 RSLinx software version 2 52 Installed Tool SRM configuration tool revision 2 5 SRM configuration tool revision 2 6 SRM configuration tool revision 3 6 Publication 1756 UM523F EN P December 2006 56 Configure the System Redundancy Module Actions Action Details 1 Choose which revision to use Do you connect your computer to ControlLogix redundancy systems revision 11 x or earlier e Yes Use revision 2 5 of the SRM Co
88. econdary Important f O forces are enabled in the offline project the software asks if you want to controller enable the forces in the controller Even if you choose No 1 0 forces stay enabled in the primary controller and become enabled in this controller after you switchover A Use RSLogix 5000 software to download the project to the controller in the secondary chassis The secondary chassis has the higher network address of the redundant pair B Go offline Important Stay offline until you finish this procedure 13 Lock the system for update Important f you abort a system lock the project in the secondary controller will be cleared and you will need to redownload the project to the secondary controller before being able to attempt another system lock A Open the SRM configuration tool for the primary chassis B Click System Update 175 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status EventLog System Update System Update Commands Lock For Update C Click Lock For Update and Yes D Wait for the system to lock It takes longer than a normal synchronization 1 57 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Update System Update Commands e Abort System Lock Initiate Locked Switchover System Update Lock Attempts The system is locked System Lock Histor Lock Initiation
89. econdary chassis PwQS Primary with Synchronized e The secondary chassis is synchronized Qualified Secondary e Skip the remaining steps in this section PwDS Primary with Disqualified e The secondary chassis is not synchronized secondary Look here ControlNET 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 105 Optimize Communication 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 Communication Types This type of communication Is Update 1 0 data not including block transfers scheduled communication Produce or consume tags Communicate with programming devices for Unscheduled communication example 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 Reestablish and monitor I O connections such as Removal and Insertion Under Power conditions this does not include normal O updates that occur during the execution of logic Bridge communications from the serial por
90. edundancy module needs 2 slots e Each chassis within a redundant pair looks the same e dentical modules same catalog number series revision and memory size e Same slot assignments system Redundancy 1757 SRM module Modules e 1 in each redundant chassis e Needs 2 slots e Needs 1757 SRCx cable 1 m 3 ft 3 m 9 ft 10 m 30 ft 50 m 150 ft and 100 m 300 ft Controllers ControlLogix5555 ControlLogix5561 ControlLogix5562 or ControlLogix5563 controllers e Which type of controller do you want to use e f ControlLogix5555 then 1 or 2 controllers in each redundant chassis e f ControlLogix5561 ControlLogix5562 or ControlLogix5563 then only 1 controller in each redundant chassis e Same type of controller throughout the chassis e Enough memory for 2 copies of all data e connections for redundancy ControlNet Modules 1756 CNB D E or 1756 CNBR D E module or modules e CPU usage J5 e CNB modules have the same keeper information e lt CNB modules See also parameter Publication 1756 UM523F EN P December 2006 ControlLogix Redundancy System Overview 23 Redundant Chassis Configuration Continued EtherNet IP Modules 1756 ENBT or 1756 EWEB modules e Which modules do you want to use 29 38 e f 1756 ENBT catalog revision greater than or equal to E01 E01 E02 F01 See the label on the side of the module or its box e f 1756 EWEB any catalog revision e Up to 2 EtherNet IP m
91. ee eee 108 PX CU OING aoa 25 do ade vet Borer eb AARNE Gone amp AOR ae Gore Gh Se eee 108 Interpret the SRM Event Log surue 4 64 84 6 we AG h ee ee 109 DEIO YON Deol 23 4 4 sue ead en ete e ee o s eed w 110 ACON eee See ne e e ne ee ae ee ere ee ee 110 Interpret SRM Events i 6 084 4 e8944 5 248 46R44 854 113 Export the SRM Event LOG sue wy edit ea aed wea 115 BelOle VOU DESIN zerrari i ke Ge ee RD 115 AO amp me yah be AD ed BE ona a ee ge ko 116 Manually Synchronize the Chassis 05 118 Optimize COMMUNICAION os s 4 eae a CERT A Deedee a Gee es 119 Choose a Greater System Overhead Time Slice 120 Enter a System Overhead Time Slice 121 Make All Your Tasks Periodic vet dee tidwiws oe es 122 Publication 1756 UM523F EN P December 2006 8 Table of Contents Update Modules and Redundant Systems Set Up EtherNet IP Communication Across Subnets Convert an Existing System to Redundancy Publication 1756 UM523F EN P December 2006 Check the Allocation of Unused Memory 123 Adjust CPU Usage for a CNB Module 123 Use RSLINX SO Ware i644 x 4k eae sk ee wh ee 124 Four Character Display 2 066 060 cee ee ees 124 Send a Message to the CNB Module 126 Store or Load a Project Using Nonvolatile Memory 126 Store a Project to Nonvolatile Memory While a Process Is RUNNING oe bo Mhe edo be Meda oes 128 Chapter 7
92. een your HMI project and the primary controller after a switchover To install the Alias Topic Switcher software use the ControlLogix Redundancy Alias Topic Switcher Exe file The file is located on the same CD as the firmware for your redundancy system The Alias Topic Switcher software runs as a service It starts automatically when you start your computer and shows up in the tool tray of your desktop Alias Topic Switcher Software Tool Tray ControlLogix Redundancy Alias Topic Switcher we he BE Sy oo He AD A a a Ta Publication 1756 UM523F EN P December 2006 150 set Up EtherNet IP Communication Across Subnets Configure a Driver to Communicate with the Primary and Secondary EtherNet IP Modules 1 Start RSLinx software RSLinx Gateway File Edit View Communications Station DDEMOPC Security Window Help 5 S Siz Available Driver Types A ua 2 Click er 3 Select Ethernet devices and choose Add New Choose a name for the new driwer 15 characters masinurn 4B_ETH 1 Station Mapping Host Name Add H 4 Accept the default name _ fi 10 98 89 56 __Add New l _ Delete 5 Type the IP address of each ENBT or EWEB module 53 Ser To add another IP address choose Add New 6 Choose and then Close 7 Click Al Browsing node 10 88 89 Workstation 4B 1FF6CB4632FE Glas Linx Gateways Ethernet Flee 10 88 89 56 fl fl 10 88 8
93. elonging to Rockwell Automation are property of their respective companies 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 j Updated information The document contains these changes E Topic Page series E information for 1756 CNB and CNBR modules Throughout manual B Redundant System Firmware Combinations 14 E Revised Procedure for Setting the Minimum Value for the Watchdog Time 100 Restrictions and Known Anomalies Appendix E Update an Online Redundant system 138 E Store a Project to Nonvolatile Memory While Process Is Running 128 E Change CNB Modules from Series D to Series E While Online 129 Publication 1756 UM523F EN P December 2006 summary of Changes 4 Notes Publication 1756 UM523F EN P December 2006 Preface ControlLogix Redundancy System Overview Design the System Install the System Table of Contents Purpose Of this Mantial 2224044 2442406489 64428 65444 11 Who Should Use this Manual 0 0 000 00 0005 11 When to Use DnissManualic as owika eee hg dotte ett Be Ak ed 11 How t Use this Manal seada Gene Gonos BY eet ge ee Gee od 11 Relate DOCUMEN 4 4 2246 bho a oa eee bs oe 12 Chapter 1 INMOCUCHOM Yuet awieeg hee ed oe OF Aree ae hE See oe 13 About the Main Parts of a Redundant System 14 Firmware Combinations That Make U
94. es Check the Enable User Program Control check box e No Uncheck the Enable User Program Control check box 1757 5SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Update Options Auto Synchronization Aways SAM Serial Number Mame Chassis ID Chassis B Description M Enable User Program Control Location C Choose Apply and then Yes to continue D Choose OK Publication 1756 UM523F EN P December 2006 64 Configure the System Redundancy Module Notes Publication 1756 UM523F EN P December 2006 Chapter 5 Configure and Program the Controller Introduction This chapter explains how to configure and program the controller for redundancy Create and maintain only one RSLogix 5000 project for the pair of redundant controllers When you download the project to the primary controller the project automatically crossloads to the secondary controller To configure and program a controller complete these tasks Topic Page Plan for Online Edits 65 Configure a Controller for Redundancy 68 Configure Communications 70 Estimate the Crossload Time of a Program 74 Minimize Scan Time 76 Maintain Data Integrity During a Switchover 82 Determine the Status of Your Redundant System 87 Condition Logic to Run After a Switchover 89 Send a Message to the SRM 91 Download the Project to the Primary Controller 95 Schedule a ControlNet Network
95. eshoot the System 1 Observe the 1756 CNB D E or 1756 CNBR D E modules in the primary chassis nay PwQs Primary with Synchronized Stop The redundant chassis are Qualified Secondary synchronized PWDS Primary with Disqualified Primary with Disqualified Secondary Go to step 2 A problem exists The cee with No Secondary Fema r ests are not 2 Observe the CNB modules in the secondary chassis Front panel Ifthe display Then So check shows 7 a CMPT Some module other than ICpt The CNB modules in the e The CNB modules in the primary and secondary chassis are the same primary and secondary revision or the CNB modules in the primary chassis are series D and chassis do not match in those in the secondary chassis are series E some way Each CNB module has a partner in the same slot in the other redundant chassis Each pair of CNB modules one in each chassis is set to the same node address Each module has compatible firmware All CNB modules in each redundant chassis are valid keepers See Update a Keeper Signature on page 107 Each module has a partner in the same slot in the other redundant this CNB module does not chassis match between the primary Each pair of controllers one in each chassis has the same memory and secondary chassis board for example 1756 L55M14 Each module has compatible firmware The RSLogix 5000 project is configured for the right type of controller and redundancy is enabled
96. et IP Communication Across Subnets ChasA_IsPrimary If set 1 then Chassis A is the primary chassis IsPrimary 0 BOOL ChasB_IsPrimary If set 1 then Chassis B is the primary chassis IsPrimary 1 BOOL IsPrimary Each bit represents the primary status for an DINT individual chassis within a redundant chassis pair 1 primary 0 not primary A single DINT tag for all the chassis uses less memory than a unique tag for each chassis Send the Message to the Appropriate Controller If Timer_RedundancyMSGs DN 1 2 seconds are up And ChasA_lsPrimary 1 Chassis A is the primary chassis And ChasA_MSG EN 0 The message is not currently enabled Then Execute the MSG instruction for the controller in Chassis A Chas4_IsPrimary Timer Redundancy S Gs DN sPrimary 0 Chas MSG EN e u MSG Type CIP Data Table Read Message Control Chast_MSG J i gt Publication 1756 UM523F EN P December 2006 set Up EtherNet IP Communication Across Subnets 161 If Timer_RedundancyMSGs DN 1 2 seconds are up And ChasB_IsPrimary 1 Chassis B is the primary chassis And ChasB_MSG EN 0 The message is not currently enabled Then Execute the MSG instruction for the controller in Chassis B LChasB_IsPrimary Timer ARedundancyMSGs 0N sPrimary 13 ChasB MSG EN e J Ea MSG Type CIP Data Table Read Message Control ChasB_MSG E R5 ChasA_IsPrimary If set 1 then Chassis A is the primary chassis I
97. executed in the program This results in an increased program scan time for a synchronized redundancy system Scan Time Program Scan Time p gt Execute Program in Crossload Results to Primary Controller secondary Controller EC Start of Program End of Program Network Addresses During a Switchover Publication 1756 UM523F EN P December 2006 Each CNB ENBT or EWEB module in a redundant chassis shares a pair of network addresses with its partner in the other chassis ControlLogix Redundancy System Overview 19 ControlNet Network set each pair of CNB modules to the same node number m A Analy s a Secondary oz le ea Chassis aa Chassis F o 24 CNB modules in the primary chassis CNB modules swap node numbers use the node number to which they are set Switchover O Secondary Primary Chassis a ti Chassis 24 CNB modules in the secondary chassis use the CNB modules swap node numbers node number to which they are set plus 1 Workstations and HMIs continue to connect Workstations and HMls continue to conne
98. f the Redundancy Object For this information GSV SSV Description Type Results of the compatibility CompatibilityResults INT GSV ie Then oD i Undetermined 1 No compatible partner Fully compatible partner INT GSV checks with the partner controller Synchronization qualification is not in progress o Unsupported 1 99 For modules that can measure their completion percentage the percent of synchronization qualification that is complete Status of the Qualification synchronization InProgress qualification process 50 For modules that cannot measure their completion percentage synchronization qualification is in progress Synchronization qualification is complete Keyswitch settings of the KeyswitchAlarm DINT GSV o Then controller and its partner Thek ich rm match or do not match Peo RERE or e No partner is present D Keyswitches do not match Position of the keyswitch of PartnerKeyswitch INT GSV CE Then the keyswitch is in the partner ooo here Status of the minor faults of PartnerMinorFaults DINT GSV This Means this minor fault the partner if the bit ModuleRedundancystate indicates that a partner Is Powerup tault present lO fault Problem with an instruction program a Periodic task overlap watchdog aa Problem with the serial port 10 Low battery Publication 1756 UM523F EN P December 2006 Attributes of the Redundancy Object 171 For this informati
99. firmware Use the same revisions that you used for the first redundant chassis Check the installation to make sure that your redundant chassis are able to synchronize Complete this procedure after you e install the system e configure the communication modules e update firmware Publication 1756 UM523F EN P December 2006 52 Install the System Actions First Chassis E E 1 Turn on the chassis power to the partner secondary chassis Turned On Turned On 2 Wait for the 1757 SRM module to complete its power up cycle Redundancy Module Redundancy Module e The SRM module takes 1 3 minutes to power up e It may also take several minutes to synchronize the secondary controller e Does 1 of the 1757 SRM modules show PRIM and the other module show SYNC e Yes Stop The system is synchronized 42801 e No There is a problem The system is not synchronized Go to step 3 3 Make sure that the Auto Synchronization option of the SRMs is set to Always For help see Chapter 4 e Does 1 of the 1757 SRM modules show PRIM and the other module show SYNC e Yes Stop The system is synchronized e No Go to Troubleshoot a Failure to Synchronize on page 105 Publication 1756 UM523F EN P December 2006 Introduction lf You just installed your system Chapter 4 Configure the System Redundancy Module This chapter explains how to set or change the configuration of a 1757 SRM module The SR
100. h messages that appear in the Massages VIEW Keeper Capable Node Active Keeper Valid keeper Keeper Signature Offline File Naa Naa Oxd25 7303 YES YES 0sd2978909 02 No YES Ond2978909 03 Unconfiqured 05 No YES 0sd2975909 06 No YES 0sd2975905 E Verify that the keeper signature has been updated Keeper Status Keeper signatures are used to identify the network configuration and ensure that all keeper capable devices are synchronized on the network This dialog provides insights into the keeper mismatch messages that appear in the Messages VIEW Keeper Capable Node Active Keeper Valid Keeper Keeper Signature Offline File NA Nd Oxd2978909 01 YES YES 0sd2978905 02 HO YES Oxd2978909 03 NO TES 0sd2978909 05 NO YES 0sd2975909 0E NO YES 0sd2978909 F Repeat steps D and E for the other CNB modules in the secondary chassis G Click Close Publication 1756 UM523F EN P December 2006 134 Update Modules and Redundant Systems Action 8 Reset the secondary CNB modules 9 Synchronize the secondary chassis The chassis are synchronized 10 Initiate a switchover 11 Replace the CNB modules in the new f secondary chassis Publication 1756 UM523F EN P December 2006 Details A Cycle power to the secondary chassis B On the Synchronization Status tab of the configuration tool verify that the modules show full compatibility 1757 5RM REDUNDANCY MODULE Slot
101. hat you e configured the project for the right type of controller e enabled redundancy see Plan for Online Edits on page 65 1 Open or create the RSLogix 5000 project for the controller Offline 1 F RUN E Ho Forces P OK M BAT Bedundancy 2 From the File menu choose Save 3 From the Communications menu choose Who Active Before proceeding to download your project do not try to match your project to your controller a Right click on your controller and select Properties E eE Baene ae A a A Mew Module M Cut Ctrl e Copy Chri c EA Paste Ctrl Delete Del Cross Reference Cbkri E Publication 1756 UM523F EN P December 2006 96 Configure and Program the Controller b Choose Advanced fz Controller Properties test23 A lel x General serial Port system Protocol User Protocol Major Faults Minor Faults Date Time Advanced SFC Execution File Redundancy Nonvolatile Memory Memory Controller Fault Handler Power Handler cnone gt system Overhead a Time slice x Security No Protection ssi Y c Leave unchecked Match Project to Controller tg Match Projectto Controller p gt serial Number fo IMPORTANT If you match your downloaded project to your controller you tie your project to your controller s serial number If you then switch over to a controller in a different chassis your project will not match the new controller s serial number
102. he memory Unused Memory usage you might not have memory for the required operation To display this dialog Advanced Redundancy Configuration 1 Choose Edit Controller Properties as Sanne nrnnesnnrnnrnnetunesneennnnnrnneunersnnennrntesanenens Memory Usage 2 On the Redundancy tab choose the Advanced button 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 p memory for online addition of Tag Logic You are unable to perform online edits OPC communications error or fail Make sure the slider is not all the way to Tags You are able to change this setting only AET while You are unable to create tags while online Make sure the slider is not all the way to Logic e offline e online in program mode Adjust CPU Usage fora a one CNB module in a redundant chassis keep CPU usage to less t 7 L CNB Module ae 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 synchronizing after a switchover To reduce the CPU usage of a module take any of these actions e Change the network update time NUT of the ControlNet network Typically increase the NUT t
103. he slot number of the CNB module Nonvolatile memory lets you keep a copy of your project on the controller Nonvolatile Memory Definitions Term Description Nonvolatile memory 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 This overwrites any project that is currently in the controller Maintain and Troubleshoot the System 127 In a redundant system store or load a project only while the secondary chassis is disqualified To store or load a project perform these procedures Storing or Loading Projects Action Details Store a Project Important If your computer is online with the controller over a ControlNet network check the CPU usage of the CNB module The CPU usage module must be less than about 75 for the store to work 1 2 Load a Project User Initiated 1 4 Put the primary controller in program mode program or remote program Open the Module Configuration properties for one of the 1757 SRM modules set the Auto Synchronization option to Conditional Disquality the secondary chassis store the project that is in the primary controller For step by step procedures on how to store a project see Logix5000 Co
104. how to design a redundancy system for a ControlLogix controller Topic Page Laying Out the System 28 Placement of a Pair of Redundant Chassis 30 Placement of the 0 31 Placement of Operator Interface Terminals 32 Additional Redundant Components 33 Checking Connection Requirements 35 Planning a ControlNet Network 35 Planning an EtherNet IP Network 38 Additional Design Considerations 41 Publication 1756 UM523F EN P December 2006 28 Design the System Laying Out the System ControlLogix Redundancy Requirements and Recommendations Use separate networks for unscheduled and scheduled Unscheduled Communication communication EtherNet IP Or ControlNet e For unscheduled communication HMI workstations message instructions use either an EtherNet IP or a ControlNet network e For scheduled communications I O produced consumed tags use a ControlNet network Scheduled Communication C O D O ControlNet 00 pego 0 Uo0do 0am amam am 1 am aap 1 pa as For unscheduled communication use lt 4 PanelView terminals per controller ControlNet network Multiple redundant chassis e Set NUT lt 90 ms pairs are OK e Set RPls lt 375 ms e f multiple ControlNe
105. iating controller has not received a response from the targeted controller For cached messages the message Instruction tries to execute three more times each attempt followed by a pause of 7 5 seconds If after 30 seconds pass the targeted controller does not respond to the initiating controller then the switchover errors out with connected time out Error 1 Extended Error 203 An example of a connected message would be CIP data table read and write messages after a connection has been established Uncached messages error out after 30 seconds if you have just initiated them because the Intiating controller never received a reply to the forward open request The error is Error 1F Extended Error 204 an unconnected time out Examples of uncached messages would include CIP generic messages and messages captured during the connection process During qualification Cached messages run with no errors A connection has been established Connected but uncached messages or unconnected messages error out with Error 1 Extended Error 301 No Buffer Memory Configure Tags for an HMI To monitor tags directly in the secondary controller not typical monitor from no more than 3 devices through a CNB module Monitor tags in a secondary controller only via e RSLogix 5000 programming 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 UM523F EN
106. ic for Chassis A aS v Alias Topic e Topic for Chassis B e n a ControlLogix redundancy system the alias topic points to the topic for the primary controller e When a switchover occurs the alias topic points to the topic for the new primary controller _____ ControlLogix Redundancy Alias Topic Switcher software Automatically reads a value in RSLinx software to determine which controller is primary It then commands the alias topic to switch to the topic for that controller v JLE 5 N 5D B E s Chassis A specific path to a controller Since each ENBT l Topic In RSLinx software a topic represents a id and EWEB module uses a unique IP address L JE create a topic for the controller in each o N redundant chassis 5 B Oo Chassis B Publication 1756 UM523F EN P December 2006 set Up EtherNet IP Communication Across Subnets 149 To keep an HMI communicating with the primary chassis e install the ControlLogix Redundancy Alias Topic Switcher Software e configure a Driver to Communicate with the Primary and Secondary EtherNet IP Modules create a DDE OPC topic for each controller e create an alias topic set up the alias topic switcher address the alias topic in the HMI project Install the ControlLogix Redundancy Alias Topic Switcher Software The ControlLogix Redundancy Alias Topic Switcher software maintains communication betw
107. ifferent subnets Do not use IP swapping You must change to the new primary address after a switchover Use ControlLogix Redundancy Alias Topic Switcher software to do this See Appendix A Primary secondary Chassis Chassis A Give the same P address subnet mask and gateway address to both modules in the redundant pair B Leave the next highest IP address open for the secondary module For example Set the primary and secondary 10 10 10 10 modules to Leave this open for the secondary 10 10 10 11 The module in the secondary chassis automatically uses the IP address of the primary 1 Worksheet for IP Swapping Pair of ENBT or EWEB Modules Configuration Pn imeacmiedundant chassrs Primary Secondary IP Address Gateway IP Address primary address 1 Address Publication 1756 UM523F EN P December 2006 40 Design the System How an EtherNet IP Module Handles a Cable Break An EtherNet IP module looks for a carrier signal only from the closest switch It does not know the health of the network beyond that point Data does not have to be flowing If the EtherNet IP module e gets the carrier signal it considers the network as OK e does not get the carrier signal it shows Link lost One switch One subnet will switchover will disqualify won t synchronize won t synchronize EtherNet IP module EtherNet IP module Shows Link lost shows Link lost RS switch prim
108. ild 030 ia 02 1756 E WEBI 05 1757 5RM ol A 10 858 88 147 1756 1 Remove HE AB_VBP 1 1789 41714 Vir Driver Diagnostics Configure Driver Device Properties Module Configuration Publication 1756 UM523F EN P December 2006 58 Configure the System Redundancy Module Action Details E 2 Set the clock A Click Configuration 175 7 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Ewent Log System Update Options Auto Syrnchronization always SAM Serial Humber a000 276 Name Chassis ID Chassis B Description W Enable User Program Control Location Date and Time SAM Current Date SAM Current Time 10 2407 AM Appii Workstation Time Chassis B Disqualified Secondary with Partner aca Hel 4uto Sy ndhronization State Never o Apply OE B Do you want to set the clock of the SRM to the clock of your computer If Then Yes Choose Apply Workstation Time and then Yes No 1 Change the date or time 2 Choose Set and then Yes C Choose OK Publication 1756 UM523F EN P December 2006 Configure the System Redundancy Module 59 Test a Switchover Use RSLinx software to manually initiate a switchover Perform this procedure after you have synchronized your system and want to test a switchover Before You Begin ControlINET NET The CNB modules in the new primary chassis show the synchronization progress after a
109. ill 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 1 0 devices through that CNB module e f 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 experience a change in state bump during a switchover e During the switchover outputs controlled by the highest priority task experience a bump free switchover For example outputs do 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 80 220 ms To take over control the secondary controller requires the same project as the primary controller It also requires up to date tag values These terms describe the process of communication between the two controllers Primary Chassis O __ 0 Crossload 1757 SRM Modules B Mgs
110. 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 nonredundant controller Publication 1756 UM523F EN P December 2006 68 Configure and Program the 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 that you create while online The rest for logic You configure how to reserve unused memory between tags and logic You do this online in program mode Reservation of Unused Memory While online create roughly the same amount of new Leave the default setting tags and new logic While online create a relatively large amount of new Drag to slider toward Tags Avoid setting the slider all the way to Tags tags but a much smaller amount of new logic e You will be unable to perform online edits e OPC communications may error or fail While online create a relatively large amount of new Drag to slider toward Logic Avoid setting the slider all the way to Logic logic but a much smaller amount of new tags you will be unable to create tags while online Configure a Controller for 1 Open or create the RSLogix 5000 project Redundancy j On the Online toolbar click the controller button Offline j No Forces MHo E
111. ization Synchronization Status Event Log Si Options Auto Synchronizatior bws SAM Seral Number B Select the Auto Synchronization option C Choose Apply and then Yes to continue D Choose OK You can direct the controller to send a message to the 1757 SRM module or block the controller from doing so Perform this procedure when you e initially configure the SRM e decide to send the SRM a message from the controller Before You Begin See page 91 for a list of messages that a controller can send to an SRM module Configure the System Redundancy Module 63 Actions Action Details 1 Open the SRM configuration tool for the A Start RSLinx software primary chassis E B From the Communications menu choose RSWho C Open all the network branches to find the 1757 SRM module in the primary chassis D Right click the SRM and choose Module Configuration Flas AB_ETH 2 Ethernet ol A 10 686 88 130 1756 ENBT A 1756 ENBT A A 10 88 86 146 1756 EWEB A 1756 EWEB A A Backplane 1756 a7 4 fl A 00 1756 L63 LOGIX5563 1756 L6g 4 13 53 2 fl Al 01 1756 CNB D 1756 CNB D 5 044 Build 030 z 02 1756 EWEB A 05 1757 5RM ol A 10 885 88 147 1756 1 Remove HE AB_VBP 1 1789 41714 Vir Driver Diagnostics Configure Driver Device Properties Module Configuration 2 Set the program control option A Click Configuration B Do you want to let a controller send a message to the SRM e Y
112. k 40 Additional Design Considerations 000048 41 Chapter 3 IMMODUCHOM 1 40 55 Sct ee ee ee BG ark we Ws Sere ee eed 43 Preliminary DOnna 43 00 d4sd eh kone ee eee Gad oo 43 Install the Chassis for the Controllers n ok oo Hees 45 Install Modules in the First Redundant Chassis 46 Install Modules in the Second Redundant Chassis 48 Publication 1756 UM523F EN P December 2006 6 Table of Contents Configure the System Redundancy Module Configure and Program the Controller Publication 1756 UM523F EN P December 2006 Install the Remote Chassis or Rails 0 0 0000000 49 Configure EtherNet IP MoOduIcs 66 08 4 46 444 3 eke ddan 50 Flash tne MOCUICS o6 0 4 asierecckeed eh ae hatha we dart we 51 Check the Installation 2 vsedug ek ceed dee beens ce Kees 51 ACON Soo 18 het end ee RGA nae ee eke ae 52 Chapter 4 MVCN OMA ane Je cetera states oye wisn witeneed ass ie RA 53 Open the SRM Configuration TOO 4 24404 4s4 2424625 53 Belore YoU BDN ereen iannu ha EAR ERER 54 ACHOS e 4 4 44 Suet ae aaa Ce a eee ee a 54 WPO DO Neer tent edt aer r eE Dey et ate ea 55 Check the Revision of Your SRM Configuration Tool 55 Betore VOU BEGIN 4 25442 t eee ae E a NE neds 55 E EARTE EE A EEEE EE E ena pokes A TEE 56 Bete oi VP COC gate S E E E E EEE E E 56 Belore YOU BOOM eeraa e ges EE gt ACION upaa t os Oo Ht Eas ER ee OO Bre eo J IE E O T E Rare E E es Be eG Ses 59 Delor YOU D
113. l A 10 668 88 130 1756 ENBT A 1756 ENBT A A 10 58 66 146 1756 EWEB A 1756 EWEB A B Backplane 1756 a7 4 fl A 00 1756 L63 LOGIX5563 1756 L6g 4 13 53 2 fl A 01 1756 CNB D 1756 CNB D 5 044 Build 030 z 02 1756 E WEBI 05 1757 5RM ff 10 886 88 147 1756 E __ Femove HE AB_VBP 1 1789 41714 Vir Driver Diagnostics Configure Driver Device Properties Module Configuration Click Event Log 1757 SRM REDUNDANCY MODULE fel Module Info Configuration Synchronization Synchronization Status Event Log System Update Auto Update Partner Log ON C OFF IE OFEN CLOSE Export Selection Chassis Module Description Classification 35685 397 1997 09 00 51 5667 F 1757 5AM 2C Autogualification Trigger Qualification 35687 3971997 09 00 46 246 0 1756 LE3 35 Partner Connection Opened State Changes 35606 3971997 09 00 46 226 0 1756 L 63 35 Partner Connection Opened State Changes Publication 1756 UM523F EN P December 2006 Maintain and Troubleshoot the System 111 Action Details 3 Look through the events of the secondary A Start with the secondary chassis chassis for a substantial change in log times e The lower list is the secondary chassis e he cause of the switchover probably happened to secondary chassis while it was the primary chassis B Look for a change of months days or hours between the log times of events e Sometimes the difference is only minutes e
114. l the two ControlLogix chassis redundant that will contain the controllers e Place the chassis within the length of a 1757 SRCx cable e Install each chassis according to the ControlLogix Chassis Installation Instructions publication 1756 INO80 e If you are converting an existing system that contains local I O modules you still need two additional chassis In a redundant system you must place all I O modules outside the redundant chassis pair Publication 1756 UM523F EN P December 2006 46 Install the System 2 For each chassis install a ControlLogix power supply according to the corresponding installation instructions Power Supply Publication 1756 PA72 ControlLogix Power Supplies Installation Instructions publication 1756 PB72 1756 INO78B 1756 PA75R ControlLogix Redundant Power Supply Installation Instructions 1756 PB75R publication 1756 IN573C IMPORTANT We recommend constant power supply to one of the redundant chassis to maintain uninterrupted operation of the redundant controller parts Install Modules in the First Redundant Chassis Soe _ce 0 Set the rotary switches of the 1 56 CNB D E or 1756 CNBR D E modules for both redundant chassis to the Same node address The primary node number is the node number of the primary chassis iii 1 Set the rotary switches of each of the 1756 CNB D E or W 0 1756 CNBR D E modules to the primary node number plus one ae For exampl
115. lLogix redundancy system Convert Local Modules to You can convert an existing system to a redundant system Remote Modules Local Module Conversions If the existing system Then Contains only I O modules that are Do not change the 1 0 configuration of the controller not in the same chassis as the controller Contains local I O 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 e reconfigure the local I O modules e replace local I O tags e replace any aliases to local I O tags Publication 1756 UM523F EN P December 2006 164 Convert an Existing System to Redundancy Reconfigure the Local I O Modules 1 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 UMO001 F I O Configuration x 1756 xxx name_of_local_module Cut local I O modules from here F x 1756 CNB x name_of_local_CNB z x 1756 CNB x name_of_remote_CNB lt q Paste the 0 modules here 2 In the controller organizer cut these modules from the local I O configuration and paste them into the remote CNB module e I O 1756 DHRIO 1756 DNB 1756 ENET or ENB 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 2 Press the
116. ler which program the primary controller is executing The scan time improvement of ControlLogix5561 5562 and 5563 controllers is less in a redundant system is than in a nonredundant system e Even though the ControlLogix5561 5562 and 5563 controllers execute logic faster they must still crossload data e Given the same project and redundant system a ControlLogix5561 5562 or 5563 controller is up to 30 faster than a ControlLogix5555 controller Configure and Program the Controller 75 Actions Action Details 1 Get the size of your crossload data Use a Get System Value GSV instruction to read the REDUNDANCY object For this information Description Type e Size of the last crossload LastData Transfer DINT This attribute gives the size of data that was or would have been crossloaded in the last scan e Size of the last crossload if you had a secondary chassis e The size in DINTs 4 byte words e You must configure the controller for redundancy e You do not need a secondary chassis Is there a synchronized secondary chassis e Yes This gives number of DINTs that was crossloaded in the last scan e No This gives number of DINTs that would have been crossloaded in the last scan e Size of the biggest MaxData Transfer DINT This attribute gives the biggest size of the LastData Transfer Size crossload Size attribute e Size of the biggest crossload if you had a secondary chassis e The size in DINT
117. m the Communications menu choose RSWho C Open the branches of your network until you find the 1757 SRM module in the primary chassis D Right click the SRM and choose Module Configuration Flas 4B_ETH 2 Ethernet el A 10 686 88 130 1756 ENBT A 1756 ENBT A A 10 88 86 146 1756 EWEB A 1756 EWEB A A Backplane 1756 a7 4 fl A 00 1756 L63 LOGIX5563 1756 L6g 4 13 53 2 fl Al 01 1756 CNB D 1756 CNB D 5 044 Build 030 z 02 1756 EWEB A 05 1757 5RM ol A 10 886 88 147 1756 E Pemove HE AB_VBP 1 1789 41714 Vir Driver Diagnostics Configure Driver Device Properties Module Configuration Maintain and Troubleshoot the System 109 Action Details 2 Check the recent synchronization attempts A Click Synchronization 1757 SRM REDUNDANCY MODULE B Do you see Edit Session In Progress under Recent synchronization Attempts Module Info Configuration Synchronization Synchronization Status EveytLog Redundancy Commands e Yes Go to step 3 Synchronize Secondary Diequality Secondary Initiate Si e No An edit session did not stop synchronization Return to Troubleshoot a Failure to Synchronize on page 105 Recent Synchronization Attempts Order Result Cause N Abort dit Session In Progress H 1 SUCCESS H 2 Success H 3 Success Then Another computer is editing the projectin Stop the edit session the controller 3 Look for the reason The project contains test edits
118. modules into the secondary chassis Important Make sure that you use the correct address slot and ControlNet tap for each module Go to step 7 Replace the CNB D modules in the secondary chassis with series E modules As you replace the modules e make sure that you set each module to the same address as the module that It is replacing e make sure that you connect the correct ControlNet tap To avoid connecting the wrong tap replace the modules one at a time and reconnect the Contro Net tap Update Modules and Redundant Systems 133 Action Details 7 Update the keeper signatures of the CNB A Start RSNetWorx for ControlNet and open the network configuration file modules B Go online with the network You do not have to browse the entire network C Select Network gt Keeper Status ControlNet_1 xc RSNetWorx for ControlNet File Edit wiew Network Device Diagnostics Tools Help 3 ta Single Pass Browse x Continuous Browse T Edits En Ee Online mo nies ee Network Up Enable Edits cheduled Band 31 66 mm Unechedule cheduled Band 34 71 Upload From Network Download to Network Hardware Download Minimum to Network Keeper Status Keeper Status Keeper signatures are used to identify the network configuration and ensure that all keeper capable devices are synchronized on the network This dialog provides insights into the keeper mismatc
119. mp 43065 1 The COP instruction moves the data into a buffer array 2 The BSL instruction uses 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 Publication 1756 UM523F EN P December 2006 Configure and Program the Controller 87 Determine the Status of You can write code that determines the status of your redundant tem Your Redundant System er Perform this procedure to e show system status on an HMI screen e condition code to execute based on system status e get diagnostic information to troubleshoot a system Actions Use a Get System Value GSV instruction to read the attributes of the REDUNDANCY object See Appendix C for a list of attributes Example 1 Ladder Diagram Get the ID of the primary chassis The primary chassis always runs the code Store the ID in the Chassis_ID_Now tag Chassis_ID_Now is a DINT Gs Get System Value Class Name REDUNDANCY Instance Hame Attribute Hame PhysicallhassislD Dest Chassis _ID_Now e Example 2 Structured Text comment W Get the ID of the primary chassis comment comment That is always the chassis that runs the code Store the ID in Chassis ID Now Chassis ID Now is a DINT code GSV REDUNDANCY PhysicalChas
120. n adds scan time to your controller This is better This rung checks Bool_B and Bool_C only once each scan Bool A MSG Type CIP Data Table Write Message Control MSG_1 a 17 MSG Type CIP Data Table Write Message Control MSG_2 J 17 Than this This rung checks Bool_B and Bool_C twice each scan One or two instructions do not add much scan time But if you do this often the extra instructions add up to a much longer scan time MSG Type CIP Data Table Write Message Control MSG_1 EJ 17 MSG Type CIP Data Table Write Message Control MSG_2 ij 17 Publication 1756 UM523F EN P December 2006 80 Configure and Program the Controller Action Details 7 Execute code only when you need it The controller crossloads a tag anytime an instruction writes a value to the tag This happens even if the value stays the same e Many instructions write a value whenever they run 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 was previously in the tag If you execute an instruction only when you need to you reduce the amount of crossload data This reduces scan time To limit the execution of an instruction e make
121. nd diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations 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 IMPORTANT Identifies information that is critical for successful application and understanding of the product Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence ATTENTION TNH avai Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present PTT aa Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures o A col oo A A A Allen Bradley RSLogix RSLogix 5000 RSView RSLinxRSNetworx DH PanelView PanelViewPlus Rockwell Automation TechConnect and VersaView are trademarks of Rockwell Automation Inc Trademarks not b
122. nd secondary chassis e Unless you are updating controller revisions do not download the project to the secondary controller While the secondary controller is synchronizing with the primary controller the 1757 SRM modules automatically let the primary controller transfer the project to the secondary controller e Once the secondary controller is synchronized the 1757 SRM modules keep the controller synchronized by providing the path for crossloading any changes that occur in the primary controller These changes include online edits force values changes to properties changes to data results of logic execution Publication 1756 UM523F EN P December 2006 18 ControlLogix Redundancy System Overview Making Online Edits Increasing Scan Time Online edits automatically crossload to the secondary controller They become inactive if a switchover happens before you assemble them into the project This stops a mistake from faulting both the old and new primary controllers Suppose you test an online edit and it causes the controller to fault In that case a switchover happens The new primary controller automatically untests the edits and goes back to the original code You have the option to keep the edits active after a switchover at the risk of faulting both controllers At the end of each program the primary controller pauses its execution to crossload the result of any output instruction that
123. nfiguration Tool Do not use revision 2 6 e No Use revision 2 6 of the SRM Configuration Tool Revision 2 6 is compatible only with revision 13 x or later ControlLogix redundancy systems You will cause the 1757 SRM module to fault if you use revision 2 6 of the tool with an revision 11 x or earlier redundancy systems Keep in mind that some features are available only in revision 2 6 or later of the configuration tool 2 See which revision you have A Open the SRM configuration tool if you have not already done so B Right click the title bar of the configuration tool and choose About 175 7 SKM REDUNDANCY MODULE GP Restore Module Info Configuration Synchronization Sunichror Mowe Identificati He Minimize ok Vendor Rockwell Automation Racin Allen Bradley ers None Product Type Redundancy Product x Close Alt F4 About Hone 1 ena q a 3 Change your revision If you need a different revision of the SRM configuration tool see Knowledgebase document G92234770 To access Rockwell Automation s Knowledgebase go to http support rockwellautomation com Important The SRM configuration tool lets you install only 1 revision on your computer at the same time To change the revision remove the revision that you installed earlier Set the SRM Clock To record significant events set clock of the 1757 SRM module Perform this procedure e after system installation e after power loss to both chassis Publi
124. nnected or broken take these actions 1 Turn off the power to the 1756 CNB B or CNBR B module 2 Replace the tap If a communication failure occurs because of a disconnected or broken tap cycle power to each primary controller on the network To prevent this situation use a 1756 CNB D E or CNBR D E module as your lowest node on the network Publication 1756 UM523F EN P December 2006 Introduction Redundant System Restrictions Appendix E Redundant System Restrictions This appendix explains the known restrictions affecting a redundant system IMPORTANT In a redundant system use an EtherNet IP network only for HM workstation communication and messaging Do not use an EtherNet IP network for e communication with I O modules e communication between devices via produced consumed tags There are several restricted features and functions in a redundant system Do not use any of these features in a ControlLogix redundancy system e Local chassis I O 1756 DHRIO or 1756 DNB modules e Event task e Inhibit a task e Motion control such as these modules 1756 HYD02 1756 L60M03SE 1756 M02AE 1756 M02AS 1756 M03SE 1756 M08SE 1756 M16SE Publication 1756 UM523F EN P December 2006 178 Redundant System Restrictions Notes Publication 1756 UM523F EN P December 2006 Numerics 1756 ENBT module see ENBT module 1756 EWEB module EWEB module 1757 SRM module see SRM m
125. no bridging e DeviceNet network via a 1756 DNB module in a remote chassis e Universal remote I O network via a 1756 DHRIO module in a remote chassis ControlNet Network Update e NUTs 80 ms 35 Times e NUTs Specified relationship to each other Number of ControlNet Nodes At least 2 nodes on each network in addition to the CNBs in the redundant chassis For 35 example each ControlNet network has at least 4 nodes ControlNet Node Assignments e Nonredundant nodes use the lowest node numbers 18 35 e CNB modules in the redundant chassis set close to the scheduled network maximum SMAX e 2 consecutive node addresses for each set of partner CNB modules one in each chassis e Switches of each partner CNB module set to the same node address Network Access Ports No devices connected to the network access ports of CNB modules in the redundant 28 chassis EtherNet IP Networks EtherNet IP networks are only for HMls workstations and messaging no control of Q 28 38 No EtherNet IP network for e control of 0 e peer interlocking produced and consumed tags Publication 1756 UM523F EN P December 2006 22 ControlLogix Redundancy System Overview Redundant Chassis Configuration Parameter Page Chassis Size Same size chassis for each pair of redundant chassis 29 Chassis Layout e Only these modules in each redundant chassis 29 e Controllers e ControlNet modules e EtherNet IP modules e System r
126. ntrolNet Network 1 Network 2 ae If the smallest Then the largest NUT on any other If the smallest Then the largest NUT on any other NUT on a network network must be less than or equal NUT on a network network must be less than or equal is ms to ms is ms to ms 2 15 21 55 3 17 22 57 4 19 23 59 5 21 24 62 6 23 25 64 7 25 26 66 8 27 27 68 9 29 28 71 10 31 29 73 11 33 30 75 12 35 31 78 13 37 32 80 14 39 33 82 15 41 34 84 16 43 35 87 17 46 36 89 18 48 37 90 90 19 50 20 52 Publication 1756 UM523F EN P December 2006 38 Design the System P anning an EtherNet IP Follow these guidelines as you plan your EtherNet IP network Network EtherNet IP Network Guidelines Guideline Details Use EtherNet IP only for HMls workstations and messaging Are communication delays OK during a switchover If Yes then continue with EtherNet IP If No then use ControlNet If you need a redundant network use ControlNet Make sure that your ENBT modules are catalog revision E01 or later Allen Bradley Ethernet IP 10 100 ControlLo CAT NO SERIES CAT REV 1756 ENBT E01 o Catalog Revision Publication 1756 UM523F EN P December 2006 In a redundant system use an EtherNet IP network only for HMI workstation and message communication Do not use an EtherNet IP network for e control of I O modules e peer interlocking produced and consumed tags Important RSLogix 5000 software lets you set up and download a
127. ntroller to change values to or from SINTs or INTs The controller does it automatically But it takes extra execution time and memory Publication 1756 UM523F EN P December 2006 82 Configure and Program the Controller Maintain Data Integrity The redundancy system guarantees a bumpless switchover for any During a Switchover logic in the highest priority task In some cases a switchover may make lower priority tasks repeat part of their scan 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 Switchover Overview 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 End of the Program in the Lower Task for example the continuous task Primary Controller co A Priority Task ae A This 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 When a switchover interrupts the execution of the primary controller the secondary controller reexecutes an interrupted program from the beginning of the program
128. ntrollers Common Procedures publication 1756 PM001 Important Do not go back online to the primary controller until you complete the rest of the steps in this procedure Go online to the secondary controller and store the project Return to the Module Configuration properties for one of the 1757 SRM modules synchronize the controllers set the Auto Synchronization option to the desired option 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 store 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 nonredundant system e The controller loads the project on power up e The controller loads the project before it activates the redundancy feature Load a Project On Corrupt Memory This Load Image option works the same as in a nonredundant system e The controller loads the project when the memory is empty or corrupt e The controller loads the project before it activates the redundancy feature Publication 1756 UM523F EN P December 2006 128 Maintain and Troubleshoot the System Store a Project to Nonvolatile Memory While a Process Is Running g Action 1 Make sure the chassis are synchronized 2 Disquality the secondary chassis 3 Store the secondary controller
129. o determine the cause Publication 1756 UM523F EN P December 2006 114 Maintain and Troubleshoot the System Event Description Module Removal Modules Chassis State Rule NRC Modules Rule Partner not on same CNet link Powerdown Time Rule Program Fault SRM OS Error SRM Serial Number Rule Standby Secondaries Rule SYS_FAIL_L Active The partner RM has been connected Publication 1756 UM523F EN P December 2006 Meaning The SRM no longer sees a module on the backplane This means that the module either experienced a nonrecoverable fault was removed from the chassis or was reset Double click the event to see the slot number of the module A check to choose a primary chassis if both chassis power up at the same time Suppose that the modules in one chassis are already in a primary state In that case that chassis becomes primary A check to choose a primary chassis if both chassis power up at the same time NRC stands for nonredundancy compliant Suppose that a module in one of the chassis doesn t support redundancy and all the modules in the other chassis do support redundancy In that case the other chassis becomes primary A primary CNB isn t able to communicate with the secondary CNB over the ControlNet network This means there is either e a network problem such as noise a poor connection or a problem with the termination e a secondary CNB that isn t connected to the network A check to choose a primar
130. o online to the new secondary controller store the project to the nonvolatile memory of the secondary controller For step by step procedures on how to store a project see Logix5000 Controllers Common Procedures publication 1756 PM001 Important Do not go back online to the secondary controller until you complete this procedure Go to the SRM configuration tool set the Auto Synchronization option to the desired option synchronize the chassis Chapter Update Modules and Redundant Systems Introduction This chapter explains how to update your module and redundant system If you want to Then see this section Page Replace 1756 CNB D or 1756 CNBR D module s with series Change CNB Modules from Series Dto 129 E modules series E While Online Change the revision of a module while minimizing the time Update a Redundant Control System 136 your system Is off Offline Update the firmware of a redundant chassis without shutting Update an Online Redundant System 138 down the process Change CNB Modules from To replace 1756 CNB D or 1756 CNBR D module s with series E Series D to Series E While modules while you are online perform this procedure IMPORTANT e Use this procedure only if your redundancy system is already at revision 15 e Replace CNB modules with CNB modules and CNBR modules with CNBR modules Otherwise your chassis will not synchronize Online e Finish this procedure once you start it Before
131. o 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 Publication 1756 UM523F EN P December 2006 124 Maintain and Troubleshoot the System To obtain status information about a CNB module e use RSLinx software e look at the four character display e send a message to the CNB module Use RSLinx Software 1 Start RSLinx software 2 Expand a network until the CNB module appears 3 Right click the module and choose Module Statistics 4 Click Connection Manager General Port Diagnostics Connection Manager Backplane Statistics Format Resource Other Connection Heres Rejects Rejects a Timeouts Open fo fof oT es e a Connection Statistics Total Connections 64 0 Ba Connections Used _ 1 Connection Utilization Number of Connections Used Buffer Statistics Max Butter Size 80000 0 S000 B0000 Buffer Utilization CPU Statistics 1 CPU Uthzation CPU Usage 42903 Four Character Display The four character display on the front of the 1756 CNB D E or 1756 CNBR D E module shows this information Ta 2797 Publication 1756 UM523F EN P December 2006 For this information about a CNB module
132. obie esea aa aE a AGA e ox 59 ACHONS 224400 ws oe aa E aa r a a eee 59 Change Auto Synchronization sasaaa aaaea 61 AO aera a a a We we ee he E E S 61 Change Program Control noaa aaa aaa 62 Before You Begin ss a ink aana aaa 62 NO ekanna aeaa Seat a a eh Sak Oe ht Sk 63 Chapter 5 MitOGUCHON 47 4 6 hin 6 r Bee A a aod eae as 65 Pho tor Online Bduss 4 44 odds iaa doled a a a 65 Decide if You Want to Keep Test Edits after ASW NOY Gls i054 h d aw ears ie oh cee k AE oe esas Ss 66 Be Aware That Finalizing Edits Removes Your Oe Aa OC Cy ratia aire ee es ee eisthe gS ee i 67 Decide How You Want to Set Aside Unused Memory 67 Configure a Controller for Redundancy 68 Configure Communications 5s 4 4 2eee5oe ee RS 4s Ss 70 Conlisure Produced Tios 2 4 ean nse edt es we 3S 70 Configure Message MSG Instructions V2 Configure Tags for an HMI 3 3254 4n 54 bob a eee awd n 73 Estimate the Crossload Time of a Program 74 Belore VOU DESIT oa 244 644 eed oh ee ee 74 PROMOS yo sgt ee A hh r a 71 gt Minimize Scan Time su 2 on biotin bs dd Bes we bho ee 76 Maintain and Troubleshoot the System Table of Contents 7 Maintain Data Integrity During a Switchover 82 Look for Array Shift Instructions 84 Look for Scan Dependent Logic 0 84 Take Preventative Actions 0 000 cee eee eee 85 Determine the Status of Your Redundant System
133. odule A add redundant components 33 additional redundant components 33 adjust CPU usage 123 attributes redundancy object 169 auto synchronization 61 BSL instruction 82 BSR instruction 82 C change CNB module from series D to series E 129 chassis install 45 check connection requirements 35 choose time slice 120 CNB module addresses during a switchover 19 change from series D to series E 129 four character display 124 install 46 requirements 22 29 usage 123 communication optimize 119 configure consumed tag 70 controller 68 EtherNet IP module 50 message instruction 72 produced tag 70 SRM module 53 connect device via NAP 16 Index connection requirements 35 consumed tag configure 0 controller configure 68 download project 95 install 46 nonvolatile memory 126 periodic task 122 program scan time 4 requirements 22 29 synchronize 51 118 system overhead time slice 120 ControlLogix redundancy system overview 13 ControlNet network keeper signature 99 107 lay out system 28 plan 35 redundant media 33 schedule 97 conversion to redundant system 163 convert local to remote modules 163 CPU usage adjust 123 crossload 16 18 estimate time for 74 D data crossload 18 integrity 82 DeviceNet network design 21 diagnose disqualification 104 switchover 104 disqualified overview 16 troubleshoot 104 download 95 E edit edit online 18 65 edit session in progress troubleshoot 108 ENBT module
134. odules in each redundant chassis within these limits If you have 1 ControlNet module 2 ControlNet modules 3 ControlNet modules 4 ControlNet modules 5 ControlNet modules Do not use more than 5 ControlNet modules Use up to 2 EtherNet IP modules 2 EtherNet IP modules 2 EtherNet IP modules 1 EtherNet IP module No EtherNet IP modules Publication 1756 UM523F EN P December 2006 24 Parameter Number of Projects Controller Properties Task Structure 1 0 Task Watchdog Time Minimizing Scan Time Data Integrity Produced and Consumed Tags Message MSG Instructions ControlLogix Redundancy System Overview RSLogix5000 Project Only one RSLogix 5000 project for the pair of redundant controllers The project automatically crossloads to the secondary controller when the secondary controller synchronizes with the primary controller e ControlLogix5555 ControlLogix5561 ControlLogix5562 or ControlLogix5563 controller 68 e Only one task at the highest priority 70 76 e Qutputs that require a bumpless switchover are in the highest priority task 70 e Requested packet interval RPI less than or equal to 375 milliseconds Larger RPIs may produce a bump at switchover Watchdog time gt 2 maximum scan time 150 ms where Maximum scan time Is the maximum scan time for the entire task when the secondary controller is synchronized e A few large programs instead of a lot of small programs
135. olatile memory 126 project to nonvolatile memory while process Is running 128 switchover Causes 15 data integrity 82 diagnose cause 104 run code after 89 test 59 troubleshoot 104 what happens to network addresses 19 20 what happens to online edits 18 synchronize controllers 51 118 diagnose failure 104 overview 16 Publication 1756 UM523F EN P December 2006 182 Index system getting information 87 install 43 overhead time slice 120 T task number of 122 set watchdog time 100 test switchover 59 Publication 1756 UM523F EN P December 2006 test edits finalize 67 what happens during a switchover 18 troubleshoot switchover 104 U update firmware 51 keeper signature 107 modules 129 offline redundant system 136 online redundant system 138 redundant systems 129 system that is already at revision 13 138 How Are We Doing 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 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 Cat No 1756 CNB D E 1756 CNBR D E 1756 ENBT Pub No 1756 UM523F EN P Pub Date December 2006 PartNo 953030 15 1756 EWEB 1756 L55 1756 L55M12 1756 L55M13 ne 1756 L55M14 1756 L55M16 1756 L55M22 1756 L55M23 1756 L55M24 1756 L61 1756 L62 1756 L63 1757 SRM Please comple
136. on GSV SSV Description Type Mode of the partner PartnerMode DINT GSV o 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 Into faulted 16 C Faulted to program In a pair of redundant PhysicalChassisID INT GSV LE Then chassis identification of a Unk specific chassis without oO aaa regard to the state of the 1 Chassis A hassis ieee 2 Chassis B Publication 1756 UM523F EN P December 2006 172 Attributes of the Redundancy Object For this information GSV SSV Description Type 1757 SRM module in this Slot number of the SRMSlotNumber chassis Size of the last LastData lransfer DINT GSV This attribute gives the size of data that was or would have crossload Size been crossloaded in the last scan Size of the last crossload if you had a secondary e The size in DINTs 4 byte words chassis e You must configure the controller for redundancy e You do not need a secondary chassis Is there a synchronized secondary chassis e Yes This gives number of DINTs that was crossloaded in the last scan e No This gives number of DINTs that would have been crossloaded in the last scan Size of the biggest MaxData Transfer DINT GSV This attribute gives the biggest size of the LastData Transfer crossload Size Size attribute Size of the biggest SSV tee if a hada e
137. on engineers e Instrumentation technicians When to Use This Manual Use this manual throughout the lifecycle of a redundancy system The lifecycle consists of these stages e Design e Installation e Configuration e Programming e Testing e Maintenance and troubleshooting How to Use this Manual This manual is divided into the basic tasks performed during the design development and implementation of a ControlLogix redundancy system e Each chapter covers a task e Tasks are organized in the sequence you will typically perform them Publication 1756 UM523F EN P December 2006 Preface 12 Related Documentation This table lists ControlLogix products and documentation that may be valuable as in programming an application Catalog Number Title Publication Number a ControlLogix ControlNet Bridge Module Installation Instructions 1756 IN571 l ControlLogix ControlNet Interface Module Release Notes 1756 RN587 1756 CNB E and ControlLogix ControlNet Bridge Module Series E Installation Instructions 1756 IN604 VAa ControlLogix ControlNet Bridge Module Series E Release Notes 1756 RN627 1756 ENBT A 1756 10 100Mbps EtherNet IP Bridge Twisted Pair Media Release Notes 1756 RN602 1756 ENBT 1756 ENBT ControlLogix EtherNet IP Product Profile 1756 PP004 ControlLogix EtherNet IP Bridge Module Installation Instructions 1756 IN019 ControlLogix EtherNet IP Communication Release Notes 1756 RN591 1756 EWEB 1756 EWEB EtherNet IP W
138. ontrolNet network 1 Go online to the controller 2 Save the project Publication 1756 UM523F EN P December 2006 100 Configure and Program the Controller Set Task Watchdog Times To give a redundant controller longer watchdog times than a nonredundant controller perform this procedure e After a switchover the secondary controller starts the scan at the beginning of the program that was running in the primary controller at the time of the switchover e The watchdog timer for the task that has the program however is not reset e A major fault happens type 6 code 1 if the watchdog timer has too little time to completely rescan the program Action Details 1 Set the minimum watchdog time for a Use this formula to set the minimum watchdog time for a task task Minimum watchdog time 2 maximum scan time 150 ms where Maximum scan time Is the maximum scan time for the entire task when the secondary controller is synchronized 2 Set the estimated watchdog time for a task E Controller Primary F Tasks E MainTask A Right click the task and choose Properties B Click Configuration lee Task Properties MainTask Program Schedule Monitor Type Continuous ha watchdog me Disable Automatic Output Processing To Reduce Task Overhead General Contiguration C Type a watchdog time that Is more than the watchdog time from step 1 Inhibit Task
139. ontroller stops at the end of every program to crossload data So the more programs of small programs that you have the more the controller stops to crossload And it often ends up crossloading the same data many times To cut down the number of crossloads e Use only one or a few programs e Divide each program into whatever number of routines makes the most sense A routine does not cause a crossload e Use the main routine of each program to call the other routines of the program e f you want to use several tasks for different scan periods put only one program in each task Remember that each program adds a crossload So use only one or a few tasks This is better a Tasks Fad MainT ask F Eb o MainProgram G Program Tags dese oo AY Mainkioautine BB added_startup P B ATR1_51_Get_Data ae ATRL 51 Send Data B ATR1_53_Process_Data a B ATR2_51_Get_Data a ATR 51 Send Data T ATR2_53_Process_Data ae ATR Control feeen E Beacons Boson CalMerge Boson Control Count _Reset a CtrlZone_O2 an CtrlZone_11 Sci CtriZone_12 Publication 1756 UM523F EN P December 2006 Than this E Tasks a ae MainTask Fr L MainProgram ao oe Ej Program Tags oo ER MainRoutine vo Eo seen B MbS_Alarms aa i B MoS_PLC_Clock en H MDS_Status bse SCAN TIME MONITOR 5 0 ATR Comms Fe HLCComms Eg ME_ omms H E Cony Configure and Program the Controller 77 Action Details 2 Delete unused t
140. opping the secondary chassis from Edit Sessions in Progress 108 synchronizing Look through a log of events to see why system switched Interpret the SRM Event Log 109 over or failed to synchronize Export specific events from the SRM event log and view them Export the SRM Event Log T15 in software such as Microsoft Excel Initiate the synchronization process Manually Synchronize the Chassis 118 e Determine why it takes a very long time to synchronize Optimize Communication 119 the secondary controller e Determine why communication with your HMls is very slow e Determine why OPC communication has errored or failed Check the Allocation of Unused Memory 123 e Determine why you are unable to create tags or edit logic while online Publication 1756 UM523F EN P December 2006 104 Maintain and Troubleshoot the System If you want to e Determine the CPU usage of a CNB module e Reduce the CPU usage of a CNB module in a redundant system e Load a project into the controller from the nonvolatile memory of the controller Store an updated project and firmware to the nonvolatile Store a Project to Nonvolatile Memory 128 memory of the controller while the process is running While a Process Is Running Diagnose a Switchover or Disqualification Start here If the secondary chassis Has power ControlINET Does not have power Publication 1756 UM523F EN P December 2006 COCOCoI vy Then see this section Page
141. or AM Serial Humber C Choose Apply and then Yes D Click Synchronization 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Update Redundancy Commands SS C chassis A Primary with Disqualified Secondary 4uto S nchrortecdtte Ste Seve F Click OK Publication 1756 UM523F EN P December 2006 132 Update Modules and Redundant Systems Action Did you already update the firmware of the series E modules 5 Update the firmware of the series E modules 6 Replace the CNB modules in the secondary chassis Publication 1756 UM523F EN P December 2006 Details Did you already update the firmware of the series E modules e Yes Go to step 6 A B No Continue with step 5 Remove the 1757 SRM module from the secondary chassis Set the address of each series E module to the address of its corresponding series D module plus one Replace each series D module with the corresponding series E module Important Make sure you connect the correct ControlNet tap to each module Use ControlFlash software and update the firmware of each series E module Remove the series E modules from the secondary chassis and set their addresses to match the original series D modules Repeat steps B E for the second set of series E modules Put the secondary SRM back into the secondary chassis Put one set of series E
142. p a Redundant System 14 Important Terms in a Redundant System 15 Primary Ghassise 234654 6h bath E we eee Eee 15 Switching from One Controller to Another 15 Network Access Poft oona ein aaa 16 Bump in Outputs During a Switchover 16 Keep the Second Controller Up to Date 16 Making Online Edie ae zerrem ekaa 655244645 22404583 18 Iieredsin e Scan TINE 6464s Beda edhe VEGA A 18 Network Addresses During a Switchover 18 ControlNet Network 44 665446449 66544 e0 865844 19 Ether Net IP NGIWORG pe 650 ian SA bed oe oe ho 20 Quick Start Checkliste 4 actin nied Sohn nore a ee Red od 21 Chapter 2 TinOCMCHOM 2 6 son zea ene nt ecto ee E Oa ag Ae ee a oe 27 Lavine Out the Sy emer eae e a a a eke he eo 28 Placement of a Pair of Redundant Chassis 30 If You Need More Than 100 Meters Between Chassis 30 Plicement Ol the TO 6 642 ware eh eotd bean ho eke aA ote a 31 Placement of Operator Interface Terminals 32 Additional Redundant Components 33 Redundant ControlNet Media 004 33 Redundant Power Supplies 0 0 000005 34 Checking Connection Requirements 005 35 Planning a ControlNet Network 2 242 eed bd een ee ed 35 Planning an EtherNet IP Network 00045 38 Worksheet for IP Swappin s lt 0 lt sac eiaeia e eens 39 How an EtherNet IP Module Handles a Cable Brea
143. preparation for a possible switchover Example 1 Ladder Diagram Get the ID of the primary chassis That is always the chassis that runs the code Store the ID in the Chassis_ID_Now tag Chassis _ID_Now DINT Gov Get System Value Class Name REDUNDANCY Instance Hame Attribute Hame PhysicallhassislD Dest Chazsis_ID Now If this is the first scan then Set the last value of the chassis ID the ID of this chassis Chassis_ ID Last DINT SFS MOY Move Source Chassis_ID Now Dest Chazsis_ID_ Last If the chassis ID changes a switchover happened If a switchover occurs then 1 Turn on the Switchover_Happened bit 2 Set the last value of the chassis ID the ID of this chassis Switchover_Happened BOOL EQ Switchover Happened Not Equal Source KRE Miny Move Source B pee aa Saree eion 1 Dest Chazsis_ID_Last 1 Continued on next page Publication 1756 UM523F EN P December 2006 90 Configure and Program the Controller If Switchover_Happened on then 1 Execute the instructions that you want to execute after a switchover 2 Turn off the Switchover_Happened bit Switchover Happened l comment comment mooo comment m comment moo code Publication 1756 UM523F EN P December 2006 Put your instructions here Switchover Happened Example 2 Structured Text Get the ID of the primary chassis That is always the
144. ring to connect the power supplies to the input modules if needed Redundant Power Supplies 1756 PA75R or 1756 PB75R Power Supply 1756 CPR Cable ControlLogix Chassis with 1756 PSCA Module D o0 1756 PA75R or 1756 PB75R Power Supply Annunciator Wiring 1756 Digital Input Module Design the System 35 Checking Connection Set aside seven connections in each redundant controller for Requirements redundancy communication e Two connections for the SRM e Five connections for the partner controller P anning a ControlNet Follow these guidelines to plan a ControlNet network Network ControlNet Network Guidelines Guideline Details Make sure the network has at least 2 nodes plus the An additional node can be redundant chassis pair e a second CNB module in the same remote chassis or in a different remote chassis e any other ControlNet device e a 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 Give the lowest ControlNet addresses to I O chassis and Do not give the lowest addresses to the redundant chassis pair other remot
145. ronization progress A Click Synchronization Status 1757 5RM REDUNDANCY MODULE 1 0 07 7 Fe to Po co rococo Secondary Readiness Compatibility 1756 L63 Disqualitted Secondary Full 1756 CNE Disqualified Secondary Full 1756 ENBT Disqualitted Secondan Full lt empty a aa lt empty si ak 1757 SAM Disqualitted Secondary Full empty Hee lt empty empty L If the controller contains a large project the system may spend some time synchronizing the secondary controller B If the Secondary Readiness remains Disqualified e Make sure the Auto Synchronization option Always 1757 5SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Upd Options Auto Synchronization Aways SAM Sera Number Harme e See Find the Cause of a Switchover or Disqualification on page 104 Publication 1756 UM523F EN P December 2006 Configure the System Redundancy Module 61 Change You an control when the 1757 SRM module tries to synchronize the n t i Auto Synchronization Ha Perform this procedure to e help synchronize the system e prevent the system from crossloading changes Actions Action Details 1 Decide when you want the system to Do you plan to manually disqualify a chassis so you can make changes synchronize e No Choose Always e Yes Choose Conditional If yo
146. ry partner PwNs Primary with no secondary partner PLU Primary locked for update SLU Secondary locked for update A module isn t able to get some information to Its partner A check to choose a primary chassis if both chassis power up at the same time Suppose that the modules in one of the chassis powered down in a disqualified secondary state In that case the other chassis becomes primary A check to choose a primary chassis if both chassis power up at the same time Suppose that a module in one of the chassis is faulted but its partner module in the other chassis is not faulted In that case the other chassis becomes primary The SRM has a problem A lock for update cannot be performed if the primary controller is faulted A lock for update or locked switchover cannot be performed If the keyswitch on either controller is not in the REM position A lock for update cannot be performed if the project names or applications are not Identical in the primary and secondary chassis A lock for update cannot be performed if test edits or SFC forces exist in the application The SRM now sees the module on the backplane This means the module has either just powered up just been put into the chassis or just finished resetting Double click the event to see the slot number of the module A module with a slot number specified in byte 0 of the extended status rejected the lock for update command See events from that module t
147. s 4 byte words e You must configure the controller for redundancy e You do not need a secondary chassis e To reset this value use an SSV instruction with a Source value of 0 Is there a synchronized secondary chassis e Yes This gives biggest number of DINTs that was crossloaded e No This gives biggest number of DINTs that would have been crossloaded see Logix5000 Controllers General Instructions Reference Manual publication 1756 RMO003 for more information on the GSV and SSV instructions 2 Estimate the crossload time Which controller do you have e f ControlLogix5555 then crossload time 0 0015 ms DINTs 1 ms overhead e f ControlLogix5561 then crossload time 0 0013 ms DINTs 1 ms overhead e f ControlLogix5562 then crossload time 0 0013 ms DINTs 1 ms overhead e f ControlLogix5563 then crossload time 0 0013 ms DINTs 1 ms overhead where DINTs Is the size of tag data to be crossloaded measured in 4 byte words Publication 1756 UM523F EN P December 2006 76 Configure and Program the Controller Minimize Scan Time To minimize a project s scan time perform this procedure Theta Do not try to get the scan time of a ControlLogix redundancy project down below about 20 milliseconds At very low scan times crossload data becomes a bigger performance burden This burden limits the minimum scan time Action Details 1 Use a few large programs instead of alot The c
148. sPrimary 0 BOOL ChasA_MSG Message instruction that transfers data between this MESSAGE controller and the controller in redundant Chassis A ChasB_IsPrimary If set If set 1 then Chassis B is the primary chassis then Chassis B is the If set 1 then Chassis B is the primary chassis chassis IsPrimary 1 BOOL ChasB_MSG Message instruction that transfers data between this MESSAGE controller and the controller in redundant Chassis B Publication 1756 UM523F EN P December 2006 162 set Up EtherNet IP Communication Across Subnets Notes Publication 1756 UM523F EN P December 2006 Appendix B Convert an Existing System to Redundancy Introduction This appendix explains how to convert an existing system to redundancy If you are adding redundancy to an existing system follow these guidelines e Changing the node number of a CNB module may affect messages tags or listen only connections in other devices Choose node numbers that have the least impact on existing communications e An existing system that contains local I O modules still requires two additional chassis A redundant system can use only I O that is in a remote chassis for example not in the same chassis as the controller We recommend that you move the existing 1750 L55Mxx controller from the original chassis and place it in a redundant chassis e Change any event tasks to periodic tasks You cannot use event tasks in a Contro
149. sages to a 1 57 SRM module Publication 1756 UM523F EN P December 2006 94 Configure and Program the Controller Configuring a Message to an SRM Continued If you want to Onthistab Forthisitem Type or select synchronize the secondary Configuration CIP Generic controller Ac r Leave blank INT tag with a value of 1 Leave blank Communication Path 1 slot_number where slot number isthe left hand slot number of the 1757 SRM module 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 CIP Generic s Source WallClockTime 0 where WallClockTime isa DINI 2 array that stores the CurrentValue of the WALLCLOCKTIME object Num Of Elements 8 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 1 57 SRM module Publication 1756 UM523F EN P December 2006 Configure and Program the Controller 95 Download the Project tothe You only have to download the project to the primary controller Primary Controller When the secondary controller is synchronized the system automatically crossloads the project to the secondary controller IMPORTANT If the secondary chassis becomes disqualified after you download the project make sure t
150. sisID Chassis ID Now Publication 1756 UM523F EN P December 2006 Configure and Program the Controller f Controller Properties MSGs_5563 Check Your Work Use the Redundancy tab of the Controller Properties window to check the code attributes It does not show all the attributes but it shows the more common attributes 1 Download and run your project 2 Open the Controller Properties window 3 Click Redundancy O x Major Faults Minor Faults DateTime Advanced SFC Execution General Serial Port System Frotocol User Protocal File Redundancy Nonvolatile Memory Memory Redundancy Enabled Redundancy Status 4 Compare the Redundancy tab with your code Chassis Id A Chassis State Primary with Suntkenized Secondary In this example the chassis ID A 1 Module State Primary with Synchronized Setesdary Module Compatibility Fully Compatible Partner Gov lt Get System Value ass Name REDUNDANCY Instarrse ame Attribute Hare 2hysicallhassislD Dest Chasse IDL Mow qe Additional Resources For more information consult these sources e Appendix C e Logix5000 Controllers General Instructions Reference Manual publication 1756 RM003 Publication 1756 UM523F EN P December 2006 Configure and Program the Controller 89 Condition Logic to Run After You can condition a section of your logic to run after a switchover a Switchover Follow these examples to create logic in
151. software that uses RSLinx 2 x software Publication 1756 UM523F EN P December 2006 Design the System 33 Additional Redundant In addition to using redundant pairs of controllers you may also add Compon ents these redundant components to your system e Redundant ControlNet Media e Redundant Power Supplies Redundant ControlNet Media Redundant ControlNet media prevents a loss of communication if a trunkline or tap is severed or disconnected It uses these components e 1756 CNBR ControlNet modules e Two identical ControlNet links Redundant ControlNet Media Components S ControlLogix Chassis with 1756 CNBR Module ControlNet Node Oo 4 a Redundant Media ControlNet Node Publication 1756 UM523F EN P December 2006 34 Design the System Publication 1756 UM523F EN P December 2006 Redundant Power Supplies Redundant power supplies let you maintain power to a ControlLogix chassis if a power supply fails Redundant power supplies use these supplies 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 wi
152. ssis For example if both chassis are on turn off one of them B Configure the EtherNet IP module in the chassis that is on e Do you see the IP address on the front of the module e lf no then return to step B e f yes then continue with step C C Repeat step B for each EtherNet IP module in this chassis A Turn off the chassis that you just configured B Turn on the other chassis C Configure the EtherNet IP module in the chassis that is on e Do you see the IP address on the front of the module e f no then return to step C e f yes then continue with step C D Repeat step C for each EtherNet IP module in this chassis Flash the Modules Redundancy Module 42801 Check the Installation Install the System 51 To flash the modules perform this procedure 1 Turn on the power to one of the redundant chassis IMPORTANT Only power up one chassis at a time Wait for the 1757 SRM module to display PRIM Flash upgrade each module in the chassis with a compatible 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 locate the node number or IP address on the front of the communication module 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
153. 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 In a pair of redundant chassis the first chassis turned on becomes the primary chassis When the secondary chassis receives power it synchronizes itself with the primary chassis When primary chassis components fail control switches to the secondary controller A switchover occurs for any of these reasons e any of these situations in the primary chassis loss of power major fault of the controller removal insertion or failure of any module in the primary chassis break or disconnection of a ControlNet tap or ethernet cable e command from the primary controller e command from RSLinx software Publication 1756 UM523F EN P December 2006 16 ControlLogix Redundancy System Overview Network Access Port Bump in Outputs During a Switchover Keep the Second Controller Up to Date Publication 1756 UM523F EN P December 2006 To connect a device to the network access port NAP of a 1756 CNB D E or 1756 CNBR D E module use an NAP that is outside of a redundant chassis Use of the Network Access Port NAP Do not connect any device to the network access port NAP of a 1 56 CNB D E or CNBR D E module in a redundant chassis e f you connect a device to the NAP of a CNB module in a redundant chassis a switchover w
154. t networks set NUTs lt specified values Remote location for all e 1 0 e DNB DHRIO amp MVI communication modules Assign the lowest node numbers to nonredundant nodes To connect a computer to the network via an NAP use a remote node At least 2 nodes in addition to the CNBs in the redundant chassis An additional node can be ns e asecond CNB module in the same remote chassis or in a different remote chassis e any other ControlNet device not required to be keeper capable Publication 1756 UM523F EN P December 2006 Design the System 29 ControlLogix Redundancy Requirements and Recommendations Continued 1756 ENBT or 1756 EWEB modules e 1 2 in each redundant chassis lt 5 total communication modules CNBs and ENBTs in each redundant chassis For 1 56 ENBT modules catalog revision must be greater than or equal to E01 E01 E02 F01 See the side of the module or Its box Requires RSLinx software version 2 50 ControlLogix5555 ControlLogix5561 ControlLogix5562 or ControlLogix5563 controllers e Same type of controller throughout the chassis e f ControlLogix5555 then 1 or 2 controllers in each redundant chassis If ControlLogix5561 ControlLogix5562 or ControlLogix5563 then only 1 controller in each redundant chassis Enough memory for 2 copies of all data 7 connections for redundancy Redundant
155. t for the first time e he revision of tool that you get depends on your version of RSLinx software e Some revisions of the SRM configuration tool are not compatible with some revisions of a ControlLogix Redundancy system The next section shows you how to see if your revision of the SRM configuration tool is right for your redundancy system Actions 1 Start RSLinx software 2 From the Communications menu choose RSWho 3 Double click the network to open it 4 Double click the communication module in the primary chassis to show the backplane 5 Double click the backplane to see its modules 6 Right click the 1757 SRM module and select Module Configuration Flag AB_ETH 2 Ethernet oe A 10 686 58 130 1756 ENBT A 1756 ENBT A A 10 88 86 146 1756 EWEB A 1756 EWEB A B A Backplane 1756 A7 4 H A 00 1756 L63 LOGIXSS63 1756 L63 4 15 53 2 fl A oL 1756 CNB D 1756 CNB D 5 044 Build 030 ja 02 1756 EWEBIA 05 1757 5RM of 10 855 88 147 1756 E Remove H E AB_VBP 1 1789 A17 14 Vir Driver Diagnostics Configure Driver Device Properties Module Configuration Check the Revision of Your SRM Configuration Tool What to Do Next Configure the System Redundancy Module 55 IMPORTANT Make sure that you check the revision of your SAM configuration tool before you use It Later revisions of the SRM configuration tool are not compatible with earlier revisions of ControlLogix redundancy systems See Ch
156. t of the controller to other ControlLogix devices via the ControlLogix backplane Publication 1756 UM523F EN P December 2006 120 Maintain and Troubleshoot the System Acceleration of Unscheduled Communication If an RSLogix 5000 project contains See Page Only a continuous task and no other tasks Choose a Greater System Overhead Time 120 This is the default task configuration slice More than one task for example at least 1 Make All Your Tasks Periodic 122 periodic 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 This table shows the ratio between the continuous task and unscheduled communication at various system overhead time slices Continuous Task and Unscheduled Communication Ratios At this time slice The continuous task And unscheduled runs for communication occurs for up to At a system overhead time slice of 20 default unscheduled communication occurs every 4 ms of continuous task time for 1 ms Legend m Task executes Task is interrupted suspended 1 ms 1 ms 1 ms 1 ms 1 ms Unscheduled Communication 4 ms 4 ms 4 ms 4 ms 4 ms Publication 1756 UM523F EN P December 2006 Maintain and Troubleshoot the System 121
157. tart the Alias Topic switcher software without access to an RSLinx activation file for example without a version of RSLinx which supports OPC this error occurs 0x80040112 The text for the message depends on your operating system 2 2 SRE HA2BRaH ee 1 In the tool tray right click the Redundancy Switch icon and choose Open Alias Topic Switching Tool 2 In the Redundancy Alias Topic Switching Tool window click x Add Hew RSLinx Alias Topic Glias Topic_1 p RSLinx OPC Topic For Chassis 4 Topic _Chassis_4 3 Type the topic names y RSLinx OPC Topic For Chassis B Topic_Chassis_6 a Alias topic Topic Currently Used by Alias Topic Chassis amp Redundancy State Unknown b Topic for the controller in Chassis A Chassis B Redundancy State Unknown c Topic for the controller in Chassis B Cancel 4 Click OK i I Redundancy Alias Topic Switching Tool Oo x RSLinx Alias Topic Chassis A Topic Chassis B Topic Active Topic Status e Edit Alias Topic 1 Topic_Chassis_A Topic_Chassis_B Active Delete Activate Deactivate Close Topic that the alias topic is currently Publication 1756 UM523F EN P December 2006 154 set Up EtherNet IP Communication Across Subnets Address the Alias Topic in the HMI Project Tag Database 4 Tag Mame JactiveT opic Type String ir Security i __ Close Description Length jaz Discard Data Source Type
158. tdown RSLinx software Restore EAR B Shutdown RSLinx Classic Me AS 11 02 AM B Update this software e 1757 SRM System Redundancy Module Configuration tool e RSLogix 5000 software e RSLinx software e RSNetWorx software e ControlFLASH firmware update kit If you are planning to uninstall version 13 of your RSLogix 5000 software wait until you have completed and validated your update Start Programs Rockwell Software RSLinx Tools EDS Hardware Installation Tool Put the keyswitch of each redundant controller to the REM position Otherwise you will not be able to update the system A Start RSLinx software B From the Communications menu choose RSWho C Open the branches of your network until you find the 1757 SRM module in the primary chassis D Right click the SRM and choose Module Configuration Flag AB_ETH 2 Ethernet el A 10 686 88 130 1756 ENBT A 1756 ENBT A A 10 88 86 146 1756 EWEB A 1756 EWEB A A Backplane 1756 a7 4 fl A 00 1756 L63 LOGIX5563 1756 L6g 4 13 53 2 fl Al O41 1756 CNB D 1756 CNB D 5 044 Build 030 T 02 1756 EWEB A 05 1757 5RM ff 10 858 88 147 1756 E __ Femove HE AB_VBP 1 1789 41714 Vir Driver Diagnostics Configure Driver Device Properties Module Configuration Update Modules and Redundant Systems 141 Action Details 5 Disqualify the secondary chassis A Click Configuration B Set Auto Synchronization to Never 1 5 SRM REDUNDANCY
159. te a locked switchover from the primary to secondary chassis Locked Switchover This is the process of transferring control from a locked primary chassis to a locked secondary chassis Locking for Update This is the process of locking a redundant system in preparation for entering the locked state Supports Locking This attribute in a redundancy object indicates whether a module supports the locking feature Only secondary chassis modules need this attribute to enable your redundancy system to enter a locked state Partner A partner is a module in a chassis that is in the same slot position as a module in the corresponding chassis A module in the primary chassis can have a partner in the secondary chassis Likewise a module in the secondary chassis can have a partner in the primary chassis Disqualified The secondary chassis or modules are in either the DSwP or DSwNP states depending on whether or not the Secondary primary chassis or modules exist Publication 1756 UM523F EN P December 2006 Update Modules and Redundant Systems 139 Teese ame When a secondary communications module is locking for updating it displays SLU When a primary communications module is locked for updating and has firmware revision 15 56 or later it displays PLU If the primary communications module s firmware is an earlier revision PwOS will be displayed when the system is locked Redundant System Relationships Different terms are unique to normal redundan
160. te the sections below Where applicable rank the feature 1 needs improvement 2 satisfactory and 3 outstanding Overall Usefulness 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 _ illustration _ feature is provided i _ example _ guideline _ other _ explanation _ definition Technical Accuracy 1 2 3 Can we be more accurate all provided information p iS correct text illustration Clarity 1 How can 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 PLEASE FASTEN HERE DO NOT STAPLE Other Comments PLEASE FOLD HERE NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 18235 CLEVELAND OH POSTAGE WILL BE PAID BY THE ADDRESSEE An P Eime DOGE WE Rockwell Automation 1 AL
161. tem 117 Action Details 3 Select the events that you want to export A Click the first event that you want to export from the primary chassis B Press and hold the Shift key and then click the last event that you want to export from the primary chassis C Repeat steps 3A and 3B for the secondary chassis 175 7 SKM REDUNDANCY 400ULE 2 Oo x Module Info in Synchronization Synchronization Status Event Log Auto Upa k Partner N Cao i Chas Event Log T Slot Module Description Classification om Tiana 12242004 16 02 27 055 2 1756 EWEB 69 Equally Able To Control State Changes T anga 12422004 16 02 27 050 S 1r5r SRAM 14 Chassis Redundancy State changed State Changes eat ed 12 4 2004 16 02 26 9367 2 1756 EWEB 4A Entered Qualification Phase 4 State Changes 43581 Taf P2004 16 02 26 91 7 5 1757 5AM 2E Qualification Complete Qualification Tangi qpr 2004 16 02 26 591 2 1756 EWEB 46 Entered Qualification Phase 3 State Changes 435 F9 2 2004 16 02 25 8592 2 1756 EWEB 3E Entered Qualification Phase 2 State Changes Tabra larer 004 16 02 24 405 2 1756 EWEB 39 Entered Qualification Phase 1 State Changes TAART Pe ee TA NA ea AA F 17R7 SAM 200 Qualification amp thenooted Qualtic atiorn gt Chassis Description Classification areal 2 4309 Ue Fr EN IC Porte Communication error 5719 4 16 l Ay 5 1E Chassis Redundancy State changed State Changes ale E au 45 47 50 8 HE 1 10 Chi Redundancy St
162. tes Publication 1756 UM523F EN P December 2006 Appendix C Attributes of the Redundancy Object Introduction This appendix explains how to use the redundancy object to learn about the status of your redundant system Attributes of the These are the attributes of the redundancy object Redundancy Object Redundant System Status and Corresponding Attributes For this information GSV SSV Description Type Redundancy status of the ChassisRedundancy INT GSV ie Then entire chassis State 16 2 Primary with synchronized secondary 16 3 Primary with disqualified secondary 16 4 Primary with no secondary 16 10 Primary locked for update INT GSV Redundancy state of the PartnerChassis Then partner chassis Redundancystate 1648 oed 16 9 Disqualified secondary with primary 16 E No partner 16 12 Secondary locked for update Redundancy status of the ModuleRedundancy INT GSV i Then ene Ae 16 2 Primary with synchronized secondary Primary with disqualified secondary 16 4 Primary with no secondary 16 6 Primary with synchronizing secondary 16 F Primary locking for update 16 10 Primary locked for update Redundancy state of the PartnerModule INT GSV o Then pannel neoundaniyotate 16 7 Synchronizing secondary Synchronized secondary 16 9 Disqualified secondary with primary 16 E No partner secondary locking for update 16 12 Secondary locked for update Publication 1756 UM523F EN P December 2006 170 Attributes o
163. the network update time NUT of the ControlNet network to estimate how long it takes your system to switchover And the NUT is Then the switchover time is The chassis loses power or 60 ms A 5 NUT MAX 2 NUT 30 other node Use a NUT that is less than or equal to 90 ms Publication 1756 UM523F EN P December 2006 A CNB module cannot gt 14 NUT MAX 2 NUT_ 30 50 communicate with any Example 1 The chassis loses power and the NUT 4 ms In that case the switchover time is approximately 60 ms Example 2 The chassis loses power and the NUT 10 ms In that case the switchover time is approximately 80 ms Example 3 You unplug the CNB from the network and the NUT 10 ms In that case the switchover time is approximately 220 ms If you use a larger network update time NUT the controller could lose its connection with a module during a switchover This could cause outputs to change state Design the System 37 Guideline Details Do the redundant chassis use more than 1 ControlNet The NUT of each network must be within the values indicated on page 29 If network you use a larger network update time NUT the controller could lose its connection with a module during a switchover This could cause outputs to e Yes See page 29 change state e No Skip this guideline Example If the NUT of this network is 5 ms Then the NUT of this network must be i 21 ms or less Aw ControlNet rn Co
164. the primary chassis D Right click the SRM and choose Module Configuration Flas 4B_ETH 2 Ethernet el A 10 686 88 130 1756 ENBT A 1756 ENBT A A 10 88 86 146 1756 EWEB A 1756 EWEB A A Backplane 1756 a7 4 fl A 00 1756 L63 LOGIX5563 1756 L6g 4 13 53 2 fl Al 01 1756 CNB D 1756 CNB D 5 044 Build 030 02 1756 EWEB A 05 1757 5RM ff 10 886 88 147 1756 E Femove HE AB_VBP 1 1789 41714 Vir Driver Diagnostics Configure Driver Device Properties Module Configuration Publication 1756 UM523F EN P December 2006 Update Modules and Redundant Systems 137 Action Details 3 Disqualify the secondary chassis A Click Configuration B Set Auto Synchronization to Never 175 7 SKM REDUSDANCT MODULE Module Info onfiguration Synchronization Synchronization Status Event Log System Update Options pnichronizatior SAM Serial Number C Choose Apply and then Yes to confirm D Click Synchronization 1757 SRM REDUNDANCY MODULE Module Into Configuration Synchronization Synchronization Status Event Log System Update Commands Sinchonge Secondary Dizquality Secondary Initiate Switchover Become E Choose Disqualify Secondary and then Yes to confirm 4 Upgrade the required firmware of the see the ControlLogix Controller and Memory Board Installation Instructions publication secondary chassis 1756 IN101 5 Make the secondary controller the new A Start
165. these parameters In this box Specify Max Scheduled Address Greatest node number to use scheduled communications on the network Max Unscheduled Address Greatest node number to use on the network 9 10 11 12 Choose OK From the Network menu choose Single Pass Browse From the File menu choose Save Select the Optimize and rewrite Schedule for all Connections button and choose OK Configure and Program the Controller 99 Check the Keepers To check the keepers perform this procedure On a ControlNet network each keeper must e take over the keeper duties if the current keeper drops off the network e use the same configuration regardless of which keeper first comes online after a major network disturbance such as a cable short or system power cycle After you schedule your ControlNet networks 1 2 Keeper Capable Node Active Keeper Valid Keeper Offline file 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 107 Save the Project for Each Controller To save the project for each controller perform this procedure 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 nonredundant on a C
166. ture of the network Inactive network keeper with valid keeper information that matches the keeper signature of the network Powering up with invalid keeper information Or offline with invalid keeper information Powering up with valid keeper information that may or may not match the keeper signature of the network or offline with valid keeper information that may or may not match the keeper signature of the network nn isthe 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 number only if the number is more than zero Bxnn e e J e Publication 1756 UM523F EN P December 2006 126 Maintain and Troubleshoot the System On this tab Configuration Communication Store or Load a Project Using Nonvolatile Memory Publication 1756 UM523F EN P December 2006 Send a Message to the CNB Module To use a Message MSG instruction to learn the CPU usage of a CNB module configure the MSG instruction CNB Module Configuration Type or select Message Type CIP Generic Service Type Custom Service Code Af Class al Instance 8 Attribute 0 source Element Tag that uses a user defined data type Members of the Data Type Tag Value Data Type offset DINT size_returned INT source Length 6 Destination INT tag in which to store the CPU usage of the CNB module 0 99 Path 1 slot number where slot number ist
167. u Need More Than 100 Meters Between Chassis To place the primary and secondary controller chassis more than 100 meters apart use a custom fiber optic cable For a custom cable follow these rules e Keep total light loss through the cable less than or equal to 7dB e Keep total length less than or equal to 4 km e Use high quality 62 5 125 micron multi mode fiber optic cable e Use professionally installed SC style connectors to connect to the 1757 SRM modules Publication 1756 UM523F EN P December 2006 Design the System 31 Placement of the 1 0 In a ControlLogix redundancy system place all I O in only these locations e Same ControlNet network as the redundant controllers no bridging to I O modules on another ControlNet network e DeviceNet network e Universal remote I O network 10 Placement Padi lala Redundant Chassis Pair G ControlNet Network N 1 0 Modules Remote Chassis B a 0 No EtherNet IP Network i HMI Yes I O No ControlNet Network HMI Yes I O Yes DeviceNet Network HMI Yes I O Yes Universal Remote 0 Network HMI Yes Publication 1756 UM523F EN P December 2006 32 Design the System Placement of Operator For operator interface terminals stay within these limitations Interface Terminals Operator Interface Terminal Limitations Network Operator Interfaces Guidelines EtherNet IP network PanelView Standard terminal Same as a nonredun
168. u choose Then Conditional The SRM keeps the synchronization command that you give it If you e synchronize the secondary the SRM always tries to keep the controllers synchronized e disqualify the secondary the SRM keeps the controller unsynchronized disqualified It does not crossload changes Never The controllers will not try to synchronize but you can still manually synchronize the controllers 2 Open the SRM configuration tool for the A Start RSLinx software primary chassis ane B From the Communications menu choose RSWho C open the branches of your network until you find the 1757 SRM module in the primary chassis D Right click the SRM and choose Module Configuration Flag AB_ETH 2 Ethernet ol A 10 858 58 130 1756 ENBT A 1756 ENBT A Fl 10 686 86 146 1756 EWEBIA 1756 EWEB A Eo Backplane 1756 A7 4 fA 00 1756 L63 LOGIX5563 1756 L63 A 13 53 2 fF 1 1756 CNB D 1756 CNB D 5 044 Build 030 02 1756 EWEB A 3 05 1757 5RM ol A 10 886 88 147 1756 E _ Remove HE AB_VBP 1 1789 41714 Vir Driver Diagnostics Configure Driver Device Properties Module Configuration Publication 1756 UM523F EN P December 2006 62 Configure the System Redundancy Module Action 3 Set the auto synchronization option Change Program Control Publication 1756 UM523F EN P December 2006 Details A Click Configuration 1757 5RM REDUNDANCY MODULE Module Info Configuration Synchron
169. u see a SYS_FAIL_L Inactive event within a few hundred milliseconds then a cable is probably disconnected or broken A communication module pulses the SYS_FAIL signal when the module loses its connection to the network Look for a Transition to Lonely event to see which module lost its connection The partner SRM powered up or become connected by the fiber optic cable Event Description The partner RM screamed Transition to Lonely Unknown Event WCT time change gt 1 second Export the SRM Event Log Chassis ID Chassis B Chassis B Chassis B Chassis B Chassis A Chassis A Meaning Maintain and Troubleshoot the System 115 The partner SRM lost power has an unrecoverable fault or was removed An SRM has circuits that hold power long enough for it to send a message to its partner over the fiber optic interconnect cable The SRM sends the message even after you remove it from the chassis This message is called a scream The scream lets the partner SRM tell the difference between a broken fiber optic interconnect cable and the power loss or removal of the primary SRM e f the fiber optic cable breaks then there isn t a switchover e f the SRM loses power or is removed then there is a switchover A communication module doesn t see any other devices on its network This usually means that the network cable of the module is disconnected or broken The event log shows Transition to Not Lonely when you reconnect the cable
170. ue of scan_count ACC Take Preventative Actions If logic seems susceptible to an upset during a switchover either place susceptible logic in the highest priority task or if the logic must remain in a lower priority task take one of these actions e Use UID and UIE Instruction Pairs e Buffer critical data Place Susceptible Logic in the Highest Priority Task This prevents the controller from sending any data to the secondary controller until the program finishes If a switchover occurs during the program the secondary controller repeats the scan using the same starting data Publication 1756 UM523F EN P December 2006 86 Configure and Program the Controller 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 ID CTU acan count CU Count Up O Counter sCcan_count DM gt Preset 1000 Accum je EQU Equal Source A can count ACE oe Source B 1000 UIE gt Buffer Critical Data This example shows the use of a buffer together with a BSL instruction e 2 photoeye Co BSL LPS Copy File Bit Shift Lett Synchronous Copy File Source array Array array butter 0 Source array buffer 0 Dest array butter 0 Control BSL ME Dest array Length 2 Source Bit Ip bit Length 2 Length Ee a
171. uration Synchronization Synchronization Status Event Lo Options Auto Synchronizatior Always SAM Seral Number Hame l Description Chassis ID Chassis B Location W Enable User Program Control e the message is unconnected Message Configuration Msqg_ 1 Configuration Communication Tag Fath Eommuncatian Method CP DH Channel Dest AR ith S 0 C A T Sauce Link Destin Leave the Connected check box clear unchecked Connected Cache Gonnections Publication 1756 UM523F EN P December 2006 Configure and Program the Controller 93 Actions Use this table to configure a message to an SRM module Configuring a Message to an SRM If you want to Onthistab Forthisitem Type or select Initiate a switchover Configuration CIP Generic y Leave blank INT tag with a value of 1 Leave blank Communication Path 1 slot_number where slot number isthe left hand slot number of the 1757 SRM module Leave the Connected check box clear unchecked You can send only unconnected messages to a 1757 SRM module Disqualify the secondary Configuration CIP Generic controller Ad y Leave blank INT tag with a value of 1 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 mes
172. us Event Log System Update Options Auto Synchronization lAlways SAM Serial Number Mame C Choose Apply and Yes 13 In the RSLogix 5000 project change the oe n the new local CNB modules to pmpAMRE ari peer arst anne General Connection RSNetwors Module Info Backplane Type 1756 CA BRE 1756 Control et Bridge Redundant Media Vendor Allen Bradley Mame Local_CNB Node Description Slot a ectronic Keping Compatible Keying Publication 1756 UM523F EN P December 2006 136 Update Modules and Redundant Systems Update a Redundant Complete this procedure to upgrade the revision of your redundant Control S tem Offlin e modules This procedure minimizes the time your process is down P during an upgrade IMPORTANT Do not connect your computer to the network access port ona CNB module in the primary chassis You will lose access to the network when you turn off power to the chassis Action Details 1 Upload and save the project Do you have an up to date copy of the project for the controller stored offline e Yes Go to step 2 e No Continue with step A A Upload the project in the primary controller B Save the project 2 Open the SRM configuration tool for the A Start RSLinx software secondary chassis B From the Communications menu choose RSWho C Open the branches of your network until you find the 1757 SRM module in
173. y chassis if both chassis power up at the same time If the two chassis powered down more than one second apart the last chassis to power down gets the first chance at being primary A controller has a major fault The SRM has a problem A check to choose a primary chassis if both chassis power up at the same time This is the final tie breaker The SRM with the lower serial number gets the first chance to become primary It becomes primary as long as the other chassis isn t more able to control the system A check to choose a primary chassis if both chassis power up at the same time Since Standby isn t available yet this check always ends in a tle A module has a nonrecoverable fault or lost its connection to the network When that happens the SYS_FAIL signal becomes true The backplane of the chassis has a SYS_FAIL signal Each module in the chassis uses this Signal to indicate a problem e The signal is normally false inactive which means that all modules in the chassis are OK e A module turns the SYS_FAIL signal true active when the module has a nonrecoverable fault or it losses its connection to the network Look for later events to find out what happened e f you see a Module Removal event shortly afterward then a module has a nonrecoverable fault Double click the Module Removal event to see the slot number of the module The SYS_FAIL signal may stay true until you cycle power or remove the faulted module e lf yo
174. you set the remote CNB module to a comm format other than i None you will receive module fault 16 000C in RSLogix5000 This fault signifies a service request error due to an invalid mode or status during a service request Configure and Program the Controller 71 Produced Tag Configuration Produced lag To the controller with the consumed tag this is the remote CNB module Redundant Chassis In the 1 0 configuration of this controller select a communication format of None for the remote CNB module Publication 1756 UM523F EN P December 2006 72 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 IF edundant Controller lt TC Pathtothe Redundant Controller Redundant Controller Lonmin Method eee foe fo eae fhennel z Destination Liat C t Soue mk Destination ade Soueelli M Cache Connections me Eo Leave this box checked Configured

1756-UM523 - Rockwell Automation

Contents

Download Pdf Manuals

Related Search

Related Contents