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ControlLogix Redundancy System

1. __ILTE MSG bz GE x IN Type CIP Generic ___ 5 N B 5 B MIT Chassis A MSG A ETE Type CIP Generic 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 157 Free running timer that triggers the execution of MSG instructions The timer runs for 2 seconds 2000 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_RedundancyMSGs DN F Timer On Delay Preset Accum TON Timer Timer_RedundancyMSGs Tag Name Description Alias For Data Type Timer_RedundancyMSGs Periodic trigger for the execution of MSG instructions Triggers MSGs every 2s TIMER Publication 1756 UM523F EN P September 2006 158 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_G
2. Network 1 ii Bee g5 88888 250 SEBEB 086 Network 2 ControlNet network for EtherNet IP network or 0 communications ControlNet network for HMI Identical pair of nt ControlLogix chassis that a a m control machine or OMO YEUNOUES process eee Computer that is connected to the network access port of a remote node 43128 What Firmware The following firmware combinations make up revision 15 56 of the ControlLogix redundancy system Combinations Make Up a i f Redundant System Module Catalog Number Series Firmware Revision ControlLogix5555 controller 1756 L55Mxx Any 15 56 ControlLogix5561 controller 1756 L61 Any 15 56 ControlLogix5562 controller 1756 L62 Any 15 56 ControlLogix5563 controller 1756 L63 Any 15 56 ControlNet bridge module 1756 CNB D 7 12 1756 CNBR gt E 1 1 1756 10 100 Mbps EtherNet IP Bridge Twisted Pair Media 1756 ENBT Any 43 1756 10 100 Mbps EtherNet IP Bridge w Enhanced Web Services 1756 EWEB Any 43 Redundancy module 1757 SRM Any 43 Publication 1756 UM523F EN P September 2006 ControlLogix Redundancy Overview 15 What Are the Important Terms in a Redundant System Term Primary Controller 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 comm
3. Secondary Primary chassis chassis 25 24 CNB modules in the secondary chassis use the CNB modules swap node numbers node number to which they are set PLUS 7 Co B Workstations and HMIs continue to connect Workstations and HMIs continue to connect to the same node number to the same node number Publication 1756 UM523F EN P September 2006 20 ControlLogix Redundancy Overview If You Have an EtherNet IP Network Set both EtherNet IP modules to the SAME IP address Port Configuration Port Configuration Primary E Secondary E hassi pace pp chassis N chassis N B B 10 10 10 10 10 10 10 11 An EtherNet IP module in the primary An EtherNet IP module in the chassis uses the IP address to which secondary chassis uses the IP address it is set to which it is set 1 in the last address segment Switchover EtherNet IP modules Secondary E Primary E chassis N chassis N B B 10 10 10 11 10 10 10 10 What Can t Do with a Don t use any of these features in a ControlLogix redundancy system 9 Redundant System j e local chassis I O 1756 DHRIO or 1756 DNB modules e event task e inhibit a task e data storage on a CompactFlash card via the controller It s OK to store a project
4. Catalog Number Title Publication Number 1756 CNB D and ControlLogix ControlNet Bridge Module Installation Instructions 1756 IN571B TONBE ControlLogix ControlNet Interface Module Release Notes 1756 RN587H 1756 CNB Eand ControlLogix ControlNet Bridge Module Series E Installation Instructions 1756 IN604A ERS ControlLogix ControlNet Bridge Module Series E Release Notes 1756 RN627C 1756 ENBT A 1756 10 100Mbps EtherNet IP Bridge Twisted Pair Media Release Notes 1756 RN602A 1756 ENBT 1756 ENBT ControlLogix EtherNet IP Product Profile 1756 PP004A ControlLogix EtherNet IP Bridge Module Installation Instructions 1756 IN019C ControlLogix EtherNet IP Communication Release Notes 1756 RN591N 1756 EWEB 1756 EWEB EtherNet IP Web Server Module Release Notes 1756 RN604E EtherNet IP Web Server Module Installation Instructions 1756 IN588A EtherNet IP Web Server Module User Manual ENET UM527D 1756 L55 ControlLogix Controller and Memory Board Installation Instructions 1756 IN101K 1756 L61 1756 L62 1756 L63 1756 M12 Moe MIS ControlLogix Controller and Memory Board Installation Instructions 1756 IN101K 1756 M14 1756 M16 1756 M22 1756 M23 1756 M24 1757 SRM B ProcessLogix ControlLogix System Redundancy Module Installation 1757 IN092D Instructions Publication 1756 UM523F EN P September 2006 Chapter 1 What s in This Chapter ControlLogix Redundancy Overview This chapter provides an overview of the Con
5. Lgx00062979 Updating a primary SRM module Updating the firmware of a 1757 SRM module in a primary chassis sometimes caused an caused an unrecoverable fault recoverable fault in the controller This happened if the controller ran out of outgoing unconnected buffers Lgx00063005 CompactFlash image caused a major A controller had a major fault if you fault e stored a CompactFlash image using a controller that was last powered down as a disqualified secondary controller and e configured the image to go to run mode after loading Lgx00063515 You couldn t download to a disqualified secondary controller xj without enough memory reserved for z i logic I Retain Test Edits on Switchover r Memory Usage Indicate whether more of the processor memory that is free after download is to be reserved for online creation of tags or logic You couldn t download to a Reserve more j ifi memory for online disqualified secondary controller Saran Tage Logo if the slider was too close to Tags l Lgx00063587 Publication 1756 UM523F EN P September 2006 Chapter 2 Design the System Use this chapter to design a redundancy system for a ControlLogix controller How to Use This Chapter To design your system complete the following tasks Topic Page Lay Out the System 30 Place the Pair of Redundant Chassis 32 Place the 1 0 33 Place Operator Interface Terminals 34 Add Additional Redundant Componen
6. A Open the SRM configuration tool if you haven t already done so B Right click the title bar of the configuration tool and choose About 1757 SRM REDUNDANCY MODULE 3 ectore es Module Info Configuration Synchronization Synchror Move Identification Size Minimize OK Vendor Rockwell Automation Ey pennies Allen Bradley i Rua i None Product Type Redundancy Product x Close AlttF4 About None w a eet 1 a 3 Change your revision Check the Version of the Configuration Tool 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 Purpose To verify the version of your 1757 SRM System Redundancy Module Configuration tool When Perform this procedure before you configure your 1757 SRM module Publication 1756 UM523F EN P September 2006 60 Configure the System Redundancy Module Actions Action Details 1 In RSLinx software browse to A Start RSLinx software 1757 SRM B Browse to your 1757 SRM 2 Identify the configuration tool version A Right click the SRM and choose Module Configuration 1757 SRM REDUNDANCY MODULE Restore
7. How an EtherNet IP Module Handles a Cable Break An EtherNet IP module looks for a carrier signal only from the closest switch It doesn t know the health of the network beyond that point Data doesn t have to be flowing If the EtherNet IP module e gets the carrier signal it considers the network as OK e doesn t get the carrier signal it shows Link lost will switchover won t synchronize shows Link lost EtherNet IP module primary chassis won t switchover will synchronize HMI can t communicate with primary chassis switch gt switch will disqualify won t synchronize EtherNet IP module shows Link lost secondary chassis won t switchover or disqualify the will synchronize HMI won t be able to communicate secondary chassis with this chassis if it becomes primary router Subnet B will switchover won t synchronize EtherNet IP module shows Link lost primary chassis switch A will disqualify won t synchronize EtherNet IP module shows Link lost secondary chassis Design the System 43 Additional Considerations Switchover Always Triggers an Event A switchover triggers an event task under the following combination of circumstances Task in a Remote Nonredundant Controller e The event task is in a nonredundant controller An Event task is n
8. Module Info Configuration Synchronization Synchronization Status EventLog System Update System Update Commands Lock For Update C Choose Lock For Update and Yes D Wait for the system to lock It takes longer than a normal synchronization 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status EventLog System Update System Update Commands krae Abort System Lock Initiate Locked Switchover r System Update Lock Attempts Cause System locked at 1 1 1997 00 06 54 652 Status Locked System Lock History Lock Initiation Time The system is locked 1 1 1997 00 06 54 652 Publication 1756 UM523F EN P September 2006 148 Maintain and Troubleshoot the System Action Details 14 Initiate a Locked Switchover 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status EventLog System Update System Update Commands Abort System Lock Initiate Locked Switchover A Choose 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 Cause Locked switchover completed at switchover completed at 2 1 Locked switchover completed at 31 Status Success Switchover Initiation Time 27 2 1 397 13 z 10 367 Locked Switchover History N 3
9. Trademarks not belonging 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 l Updated Information The document contains the following changes Topic Page Series E information for 1756 CNB and CNBR modules Throughout manual Redundant System Firmware Combinations 14 Compatible Software Versions 26 B Enhancements in Revision 15 56 26 B Corrected Anomalies in Revision 15 56 27 Revised Procedure for Setting the Minimum Value for the Watchdog Time 102 Restrictions and Known Anomalies Appendix E B Update a System That Is Already at Revision 13 142 Store a Project to Nonvolatile Memory While Process Is Running 139 _ Change CNB Modules from Series D to Series E 131 Publication 1756 UM523F EN P September 2006 Summary of Changes 4 Notes Publication 1756 UM523F EN P September 2006 ControlLogix Redundancy Overview Design the System Install the System Table of Contents Chapter 1 What s in This Cate a aah e eek Se Oe DM ee woh 13 What Are The Main Parts of a Redundant System 13 What Firmware Combinations Make Up a Redundant Systemi s yatta wed a ke ce eee ace eS 14 What Are the Important Terms in a Redundant System 15 How Do I Assign the Pri
10. e 1757 SRC1 e 1757 SRC3 e 1757 SRC10 e 1757 SRC50 e 1757 SRC100 Publication 1756 UM523F EN P September 2006 Install the Remote Chassis Install the System 51 You must install all I O modules and additional types of communication modules in remote chassis or on DIN rails The or Rails following example shows a remote 1756 chassis You can use any type of chassis or device that you can connect to the ControlNet network eo ii DeviceNet network LI CIE FLT LIC IE S TaS C D 5 NIN 5ININ R N 10 modules N 5 B B 5 B B M B B T T SY 42197 Other ControlNet node if 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 after the failure of a Contro Net 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 mo
11. e During the switchover outputs controlled by the highest priority task experience a bump free switchover For example outputs don t revert to a previous state e Outputs in lower priority tasks may experience a change of state The switchover time of a redundant system depends on the type of failure and the network update time NUT of the ControlNet network For a NUT of 10 ms the switchover time is approximately 80 ms to 220 ms To take over control the secondary controller requires the same project as the primary controller It also requires up to date tag values ControlLogix Redundancy Overview 17 The following terms describe the process of communication between the two controllers Term Description CrossloadC 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 Synchronize 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 contr
12. Allen Bradley ControlLogix Redundancy System 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 and diagrams N
13. Go to step 7 e No Continue with step 6 Publication 1756 UM523F EN P September 2006 134 Maintain and Troubleshoot the System Action 6 Update the firmware of the series E modules Details A Remove the 1757 SRM module from the secondary chassis B 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 thru E for the second set of series E modules Put the secondary SRM back into the secondary chassis Put one set of series E modules into the secondary chassis Important Make sure that you use the correct address slot and ControlNet tap for each module Go to step 8 7 Replace the CNB modules in the secondary chassis Publication 1756 UM523F EN P September 2006 Replace the CNB 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 s replacing e make sure that you connect the correct ControlNet tap To avoid connecting the wrong tap replace the modules one at a t
14. B From the Communications menu choose RS Who 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 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Update Identification Status Vendor Rockwell Automation Allen oe OK Bradley Major Fault None Product Type Redundancy Product Publication 1756 UM523F EN P September 2006 Maintain and Troubleshoot the System 133 Action Details 4 Disqualify the secondary chassis A Click Configuration B Set Auto Synchronization to Never 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Update Options Auto Synchronization v SBM Serial Number 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 Disqualify Secondary E Choose Disqualify Secondary and then Yes Initiate Switchover The secondary chassis is disqualified lt Chassis 4 Primary with Disqualified Secondary Uuto oynchronizatton Stater tieve F Choose OK 5 Did you already update the firmware of Did you already update the firmware of the series E modules the series E modules e Yes
15. Configure and Program the Controller Chapter 5 After having installed a system use this chapter 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 the following tasks Topic Page Plan for Online Edits 69 Configure Communications 74 Estimate the Crossload Time of a Program 77 Minimize Scan Time 79 Maintain the Integrity of Your Data During a Switchover 85 Determine the Status of Your Redundancy System 90 Condition Logic to Run After a Switchover 91 Send a Message to the SRM 94 Download the Project to the Primary Controller 98 Schedule the ControlNet Networks 98 Set the Task Watchdog Times 102 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 September 2006 70 Configure and Program the Controller 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 i Tag 3 Tag4 Tag_5 Test Edits 3 E E C3 i Tag_3 Tag_5 R R If te
16. Never The controllers won t try to synchronize but you can still manually synchronize the controllers 2 Open the SRM configuration tool for the primary chassis A Start RSLinx software B From the Communications menu choose RSWho C open the branches of your network until you find the 1757 SRM module in the primary chassis D Right click the SRM and choose Module Configuration 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log Identification Status Vendor Rockwell Automation Merete atete OK Allen Bradley Major Fault Nor Product Type Redundancy Product Publication 1756 UM523F EN P September 2006 66 Configure the System Redundancy Module Action Details 3 Set the auto synchronization option A Click Configuration Module Info i ynchronization Synchronization Status Event Log Options MATE Always SRM Serial Number ee B Select the Auto Synchronization option C Choose Apply and then Yes to continue D Choose OK Change the Program Purpose Control Option To let the controller send a message to the 1757 SRM module or block the controller from sending a message to the 1757 SRM module When Do this procedure when you initially configure the SRM e decide to send the SRM a message from the controller Before You Begin See page 94 for a list of messages that a controller can send to an SRM module Pu
17. RSLogix 5000 Project Parameter Criteria Page 1 Number of projects Only one RSLogix 5000 project for the pair of redundant controllers The project automatically 69 crossloads to the secondary controller when the secondary controller synchronizes with the primary controller 2 Controller properties e ControlLogix5555 ControlLogix5561 ControlLogix5562 or ControlLogix5563 controller 72 e Redundancy enabled 3 Task structure e Only one task at the highest priority 74 79 e f more than one task all tasks periodic 123 4 1 0 e Qutputs that require a bumpless switchover are in the highest priority task 74 e Requested packet interval RPI less than or equal to 375 milliseconds Larger RPIs may produce a bump at switchover 5 Task watchdog time Watchdog time gt 2 maximum_scan_time 100ms 102 Publication 1756 UM523F EN P September 2006 24 ControlLogix Redundancy Overview RSLogix 5000 Project Continued Parameter Criteria Page 6 Minimizing scan time e A few large programs instead of a lot of small programs 79 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 7 Data integrity Special treatment for 85 e Bit Shift Left BSL and Bit Shift Right BSR instructions e FIFO Unload FFU instructions e Log
18. Topic List Data Source Data Collection Advanced Com Refresh IV Autobrowse Workstation AB 1FF6CB4632FE Ba Linx Gateways Ethernet s AB_ETH 1 Ethernet 10 88 89 55 1756 ENBT A4 1756 ENBT 10 88 89 56 1756 ENBT A4 1756 ENBT Backplane 1756 A7 4 i 02 1756 L55 4 LOGIX5555 17 03 1756 CNB D 1756 CNB D D DDE OPC Topic Configuration Project Default Topic List Data Source Data Collection Advanced Com Topic_Chassis_A IV Autobrowse Topic_Ch Workstation AB 1FF6CB4632FE Linx Gateways Ethernet Zs AB_ETH 1 Ethernet Gif 10 88 89 55 1756 ENBT A 1756 ENB1 Publication 1756 UM523F EN P September 2006 154 Set Up EtherNet IP Communication Across Subnets Create an Alias Topic 1 In RSLinx software choose DDE OPC gt RSLinx Gateway Alias Topic Configuration File Edit view Communications Station DDE OPC Security Window Help amp S18 lR x 2 Type a name for the alias topic that will communicate with this pair of redundant controllers Configure Alias Topics List of Alias Topics Alias Configuration Alias Name Alias_Topic_1 Aliased Topics Topic_Chassis_A Topic_Chassis_B 3 Add the topic for each redundant controller to the Aliased Topics list Available Topics 42373 AFO2_01 Change_UCBs To add a topic select the topic and choose
19. f Yes then continue with EtherNet IP e f No then use ControlNet Communication stops over an EtherNet IP network with your controllers and HMs during a switchover e You won t be able to communicate with them for up to a minute e The actual delay depends on your network topology If you need bumpless communication use a ControlNet network 3 If you need a redundant network use ControlNet 4 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 CE Catalog revision Publication 1756 UM523F EN P September 2006 2 EtherNet IP modules in same chassis doesn t 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 42 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 To 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 won t synchronize Guideline 5 Decide how to handle IP addresses Details lf BOTH redundant chassis are on Design the System 41 Then Same subnet Switch Primary Secondary chassis chassis Use IP swapping During
20. 1757 SRM My Network eee E n 1756 communication module 7 2 From the Communications menu choose RSWho L 3 Double click the network to open it 4 Double click the communication module in the primary chassis to show the backplane m 5 Double click the backplane to see its modules Publication 1756 UM523F EN P September 2006 6 Right click the 1757 SRM module and select Module Configuration Configure the System Redundancy Module 57 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log Identification r Status Vendor Rockwell Automation General State OK Allen Bradley Major Fault Non Product Type Redundancy Product What to Do Next IMPORTANT Make sure that you check the revision of your SRM configuration tool before you use it Later revisions of the SRM configuration tool aren t compatible with earlier revisions of ControlLogix redundancy systems See Check the Revision of Your SRM Configuration Tool on page 57 Check the Revision of Your Purpose 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 ll cause the 1757 SRM module to fault if you use revision 2 6 o
21. Attribute 0 Source Element Tag that uses a user defined data type Members of the data type Tag value Name Data type offset DINT 0 size_returned INT 2 Source Length 6 Destination INT tag in which to store the CPU usage of the CNB module 0 99 Communication Path 1 slot_number where slot _ number is the slot number of the CNB module Publication 1756 UM523F EN P September 2006 Maintain and Troubleshoot the System 131 Change CNB modules from Complete the following procedure to replace 1756 CNB D or Series D to Series E 1756 CNBR D module s with series E modules 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 won t synchronize e Finish this procedure once you start it e Each module must be the same series as its partner in the other redundant chassis If you replace a module with a different series you must replace the partner module with the same series Before 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 If the CNB modules are And you Then Revision 11 1 or later p gt Goto Actions and start the procedure You don t need to update the firmware of the modules Not revision 11 1 or later Have a nonredundant 1 Add the revision 11 EDS fi
22. Automation representative 7 Wait several minutes for the system to try to synchronize 8 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 108 Publication 1756 UM523F EN P September 2006 108 Maintain and Troubleshoot the System Troubleshoot a Failure to Synchronize E IMPORTANT If the steps in this section do not correct the situation check the IMPORTANT usage of the CNB modules See Adjust CNB Usage on page 127 e f the chassis still doesn t synchronize try to manually synchronize it See Manually Synchronize the Chassis on page 122 1 Look at the 1756 CNB D E or 1756 CNBR D E modules in the primary chassis Primary CNB Front panel If It means So do this C O PWS Primary with Synchronized Stop The redundant chassis are Seats lRE Qualified Secondary synchronized Look here p PwDS Primary with Disqualified Secondary Go to step 2 A problem exists The ay PwNS Primary with No Secondary ee ae 2 Look at the CNB modules in the secondary chassis Publication 1756 UM523F EN P September 2006 Front panel Secondary CNB ControlNET Maintain and Troubleshoot the System 109 lfthe display Then So check the following shows ICpt The CNB modules
23. CPR cables to connect the power supplies to the 1756 PSCA adapter e User supplied annunciator wiring to connect the power supplies to the input modules if needed oof 1756 PA75R or 1756 PB75R oo 1756 PA75R or 1756 PB75R 1756 CPR cable 71 cay Annunciator wiring 1756 digital ControlLogix chassis with ae input ae 1756 PSCA module m Publication 1756 UM523F EN P September 2006 Design the System 37 Check 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 Plan the ControlNet Follow these guidelines to plan a ControlNet networks Networks Guideline Details 1 Make sure the network has at least 2 nodes plus the redundant chassis pair An additional node can be e asecond 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 2 Give the lowest ControlNet addresses to 1 0 chassis and other remote chassis Don t give the lowest addresses to the redundant chassis pair If y
24. ControlNet network Use the network update time NUT of the ControlNet network to estimate how long it takes your system to switchover If And the NUT is Then the switchover time is The chassis loses power or 6 ms or less 60 ms a mbunlotels 7 ms or more 5 nuT MAX 2 NUT_ 30 A CNB module can t gt 14 NuT MAX 2 NUT_ 30 50 communicate with any other node 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 5 Use a NUT that is less than or equal to 90 ms Publication 1756 UM523F EN P September 2006 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 39 Guideline Details 6 Do the redundant chassis use more than 1 ControlNet The NUT of each network must be within the values indicated on page 31 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 31 change state e No Skip this guideline Example If the NUT of this network is 5 ms Then the NUT of thi
25. Memory While firmware to the nonvolatile memory of the controller This procedure i lets you store a project while the process is running a Process Is Running the nonvolatile memory of a 1756 L55M2x controller if you ve updated it to revision 15 Otherwise the controller will have an unrecoverable fault solid red OK light and clear the project from its memory IMPORTANT Use this procedure only with a 1756 L6x controller Do not use Action Details 1 Make sure the chassis are synchronized Synchronize the chassis if they aren t already synchronized 2 Disqualify the secondary chassis A Open the SRM configuration tool for the primary chassis ow Set the Auto Synchronization option to Never C Disqualify the secondary chassis 3 Store the secondary controller s project A Go online to the secondary controller ow 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 4 Initiate a switchover A Go to the SRM configuration tool ow Synchronize the chassis C Initiate a switchover 5 Store the new secondary controller s A Go online to the new secondary controller project ive Store the project to the nonvolatile memory
26. Module Removal 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 Modules Chassis State Rule 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 NRC Modules Rule 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 Publication 1756 UM523F EN P September 2006 118 Maintain and Troubleshoot the System Event description Partner not on same CNet link 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 Powerdown Time Rule A check to choose a primary 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 Program Fault
27. My Reals Real_3 REAL Than this Tag Name amp Type One user defined data type for all the My Data UDT data The controller crossloads these FF My_Data Constant_1 DINT 28 bytes every scan F My_Data Constant_2 DINT My_Data Cosntant_3 DINT My Data Bool_1 BOOL My_Data Bool_2 BOOL My_Data Bool_3 BOOL My_Data Real_1 REAL My Data Real_2 REAL My Data Real_3 REAL 9 Use DINT tags instead of SINT or INT tags Publication 1756 UM523F EN P September 2006 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 f the destination is a SINT or INT tag the controller usually changes the value back to a SINT or INT value e You don t have to program the controller to change values to or from SINTs or INTs The controller does it automatically But it takes extra execution time and memory Configure and Program the Controller 85 Maintain the Integrity of The redundancy system guarantees a bumpless switchover for any logic in the highest priority task In some cases a switchover may Your Data During a make lower priority tasks repeat part of their scan This has to do with Switchover how data crossloads from the primary controller to the sec
28. Put the controller in the redundant chassis Otherwise the controller will have a an unrecoverable fault After you update it the first time you can update it in the redundant chassis from then on Nonexample The controller is already running in your system You want to update it to a later revision In this case leave it where it is and update it there Give an SRM module several minutes or It takes several minutes to update a 1757 SRM module and the module resets itself at more to update least 4 times An SRM module with 3 37 or earlier firmware may become inoperative if you interrupt the update process Update Status Catalog Number 1757 SRM 4 SerialNumber 00301FF0 Current Revision 4 3 5 View Log New Revision 4 3 5 ymo Wait until you see this box Status Help turn green and say Update complete Repeat If the update fails leave the power on and try again The update failed if you see e Update Status window turn red and say the update failed e OK LED on the SRM module is red flashing and the 4 character display is blank chassis are disqualified before you try to actions before you try to synchronize the chassis Wait at least 45 seconds after the redundant If your secondary chassis becomes disqualified or you manually disqualify it do these synchronize them e Make sure the synchronization status of the primary modules is full compatibility e Wait at least 45 seconds before you give the command to syn
29. Switchover or 106 e Find why secondary chassis became disqualified Disqualification Find why the secondary controller fails to synchronize Troubleshoot a Failure to Synchronize 108 See if the keeper signature of a CNB module is stopping the Update a Keeper Signature 110 secondary chassis from synchronizing See if a computer is stopping the secondary chassis from See if an Edit Session Is in Progress 111 synchronizing Look through a log of events to see why system switched Interpret the SRM Event Log 113 over or failed to synchronize Export specific events from the SRM event log and view them Export the SRM Event Log 119 in software such as Microsoft Excel Initiate the synchronization process Manually Synchronize the Chassis 122 e Determine why it takes a very long time to synchronize Optimize Communication 123 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 127 e Determine why you are unable to create tags or edit logic while online Publication 1756 UM523F EN P September 2006 106 Maintain and Troubleshoot the System If you want to Then see this section Page e Determine the CPU usage of a CNB module Adjust CNB Usage 127 e Reduce the CPU usage of a CNB module e Store a project to the nonvolatile memory of a controller Store or Load a Project
30. Topic Active Topic Status _ i Alias_Topic_1 Topic_Chassis_A Topic_Chassis_B Topic_Chassis_A Add New Delete Activate Deactivate Close L Topic that the alias topic is currently using Publication 1756 UM523F EN P September 2006 156 Set Up EtherNet IP Communication Across Subnets Address the Alias Topic in the HMI Project i Tag Database Tag Name ActiveT opic Type Sting Security Bi Description Length 82 Discard JEW m Data Source Type Device C Memory Help Node Name IR edundant_Chassis E Address Alias_Topic_1 ActiveT opic at FL Alar 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 re not using IP swapping any controller that sends a message to a redundant chassis has to point to the new primary chassis after a the Primary Chassis at E xX N B j Sie pe IP Address A es E a IP Address B LIFE L JE 5 N 5 N 5 B 5 B Chassis A Chassis B Switchover Primary p 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 September 2006 Set Up EtherNet IP Communication Across Subnets
31. Using Nonvolatile 137 in a redundant system Memory e Load a project into the controller from the nonvolatile memory of the controller Replace 1756 CNB D or 1756 CNBR D module s with series Change CNB modules from Series D to 131 E modules Series E Change the revision of a module while minimizing the time Update a Module 140 your system is off Store an updated project and firmware to the nonvolatile Store a Project to Nonvolatile Memory 139 memory of the controller while the process is running While a Process Is Running Update the firmware of a redundant chassis without shutting Update a System That Is Already at 142 i down the process Revision 13 Find the Cause of a Purpose Switchover or Disqualification To find and fix the cause of an unplanned switchover or loss of synchronization When Perform this procedure when e an unplanned switchover happens e a chassis that was synchronized becomes disqualified Actions ControlNET Start here FE primary chassis show PwQs e No Go to step 2 1 Do the 1756 CNB D E or 1756 CNBR D E modules in the e Yes Go to Interpret the SRM Event Log on page 113 2 Does any module in the primary chassis show PwNS e Yes Go to step 3 e No Goto step 6 Publication 1756 UM523F EN P September 2006 If the secondary chassis Has power Maintain and Troubleshoot the System 107 3 Use the following table to troubleshoot the s
32. ah we aide ed Acad 63 Change the Auto Synchronization Option 65 PUP DOSE eg menee da a Taa PCE AC gh 65 AVA e a TORSE e elvis eth arde E eed Goa E hed ae aha one 65 ACUOSA E EAA veka Apa E AeA OE Ae 65 Configure and Program the Controller Table of Contents 7 Change the Program Control Option 66 Purpose ted Rai Fuel iy Ou ae Gane cede eat dant Bk 66 AVERY oy d toi plone ck hie ete Bd th aol adhe g Med 66 Before Yo Besinn lt 2 renoir ierde inirapan eae 66 ACHODS ea a eee Oe ee Tee EEA Se a R ERG 67 Chapter 5 When to Use This Chapter n tea ne Pty Aah eae 69 How to Use This Chapter 24 40 808 ove eee ee a 69 Plan for Online ECU iehe sachet buch dda gue es BeOS Be 4h eine Ree 69 Decide if You Want to Keep Test Edits after BS VALCO Vee hay aie resi acd on aha Ate ERA R 8 70 Be Aware That Finalizing Edits Removes Your Original Logic sasaaa Fak Oe eh ee Bee gh OS 71 Decide How You Want to Set Aside Unused Memory 71 Configure a Controller for Redundancy 72 Configure Communications 0 00 00000002 eae 74 Configure Produced Tags w 26 0c fee a ee atk Gea cus 74 Configure Message MSG Instructions 76 Configure Tags for an HMI fscinc eed Oe ae OR Oe es 76 Estimate the Crossload Time of a Program 77 PUTPOSES a eb DA E EE Re eae De 77 NWS 9 aurere sarpone ed pees Boke CNG Get 6h a a a sy Z7 Before you begin Pe a note tM
33. 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 September 2006 3 Convert an Existing System to Redundancy 169 Replace in Tag Collections x Find What e 7 is Text Only find Wert v Replace With x A Heplace Replace til Find Where fai Tags X Close M Wrap Direction I Match Whole Word Only C Up Down Find Within Tags 3 Type Local 4 Type the name of the CNB module that is in the remote chassis 5 Select All Tags 6 Choose Find Within gt gt m wihi Y a O4Oo s4 lt lt Find Within ags Options Malas lt Base Tag Description Name OType Components 7 42815 7 Check Alias 8 Choose Replace All 9 Choose Close Publication 1756 UM523F EN P September 2006 170 Convert an Existing System to Redundancy Notes Publication 1756 UM523F EN P September 2006 Appendix C Attributes of the Redundancy Object Use the redundancy object to learn about the status of your redundancy system For this information Get this attribute Data GSV SSV Description type Redundancy status of the ChassisRedundancy INT GSV lf Then epUese assi
34. completion percentage synchronization qualification is in progress 100 Synchronization qualification is complete Keyswitch settings of the KeyswitchAlarm DINT GSV If Then controller and its partner Rae match or Gano cate 0 One of the following e The keyswitches match e No partner is present 1 Keyswitches do not match Position of the keyswitch of PartnerKeyswitch DINT GSV If Then the keyswitch is in the partner 0 Unknown 1 RUN 2 PROG 3 REM Status of the minor faults of PartnerMinorFaults DINT GSV This Means this minor fault the partner if the bit ModuleRedundancyState F a indicates that a partner is 4 Problem with an instruction program present 6 Periodic task overlap watchdog 9 Problem with the serial port 10 Low battery Publication 1756 UM523F EN P September 2006 Attributes of the Redundancy Object 173 For this information Get this attribute Data GSV SSV Description type Mode of the partner PartnerMode DINT GSV lf Then 16 0 Power up 16 1 Program 16 2 Run 16 3 Test 16 4 Faulted 16 5 Run to program 16 6 Test to program 16 7 Program to run 16 8 Test to run 16 9 Run to test 16 A Program to test 16 B Into faulted 16 C Faulted to program In a pair of redundant PhysicalChassisID INT GSV lf Then chassis identification of a 0 Unk specific chassis without palit regard to the state of the 1 Chassis A chassis 7 2 Chassis B Publication 1756 UM523F E
35. controller crossloads only 4 bytes These 3 BOOL tags take 12 bytes total 3 tags x 4 bytes tag 12 bytes 7 Bool_Tag_1 BOOL Bool Tag_2 BooL Bool_Tag_3 BOOL 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 September 2006 Action Details 4 If you ve already created individual tags change them to aliases C Keep pointing your logic to the individual tag names 5 Keep user defined data types as compact as possible Configure and Program the Controller 81 If you ve already created individual tags change them to aliases for elements of an 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 L Tag Name Alias For Bool_Array Bool_Tag_1 Bool_Array 0 Bool_Array 0 Bool_Tag_2 Bool_Array 1 Bool_Array 1 Bool_Tag_3 Bool_Array 2 Bool_Array 2 Bool_Taq_1 Bool_Tag_2 lt Bool_Array O gt lt Bool_Array 1 gt Put like data types together when you lay out a user defined data type 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 B
36. depends on how much The length of time for the crossload depends on the how much data the primary controller data changed 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 controller which program the primary controller is executing In a redundant system a ControlLogix5561 The scan time improvement of ControlLogix5561 5562 and 5563 controllers is less ina 5562 or 5563 controller is up to 30 faster redundant system is than in a nonredundant system than a ControlLogix5555 controller 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 Publication 1756 UM523F EN P September 2006 78 Configure and Program the Controller 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 Get this attribute Data Description Type e Size of the last crossload LastDataTransfer DINT This attribute gives the size of data that was or would have e Size of the last crossload S e been crossloaded in the last scan if you had d ee ESE e The size in DINTs 4 byte w
37. 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 the following 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 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 Check the Keepers 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 Publication 1756 UM523F EN P September 2006 comes online after a major network disturbance such as a cable short or system power cycle Configure and Program the Controller 101 After you schedule your ControlNet networks 1 2 Keeper Capable Node Active Keeper Valid Keeper offline file N A N A 01 No Yes 02 Yes Yes 1 Make sure the network shows all keeper capable nodes 2 Make sure that each node is a valid keeper For more information see Update a Keeper Signature on page 6 Save the Project for Each Controller After your schedule your ControlNet networks save the online project
38. information ale is correct F text F illustration Clarity 1 2 3 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 Other Comments PLEASE FASTEN HERE DO NOT STAPLE PLEASE FOLD HERE BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 18235 CLEVELAND OH POSTAGE WILL BE PAID BY THE ADDRESSEE Allen Bradley etecrnicl ROCKWELL SOFTWARE DOGE Rockwell Automation 1 ALLEN BRADLEY DR MAYFIELD HEIGHTS OH 44124 9705 NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES PLEASE REMOVE Rockwell Automation Rockwell Automation provides technical information on the web to assist you in using our products At http support rockwellautomation com you can Support find technical manuals a knowledge base of FAQs technical and application notes sample code and links to software service
39. interface terminals stay within these limitations Terminals For this network And any of these operator interfaces EtherNet IP network PanelView Standard terminal Follow these guidelines Same as a nonredundant system e PanelView Plus terminal e VersaView industrial computer running a Windows CE operating system e Use RSLinx Enterprise software revision 3 0 or later 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 Enterprise software Use RSLinx Enterprise software revision 3 0 or later Use IP swapping Keep the HMI and both redundant chassis on the same subnet RSView Supervisory Edition software with RSLinx 2 x software RSView 32 software Any other HMI client software that uses RSLinx 2 x software Limit the number of RSLinx servers that a controller uses to 1 ideal to 3 maximum PanelView Standard terminal PanelView 1000e 1400e terminal Contro Net network PanelView Plus terminal VersaView industrial computer running a Windows CE operating system Do your terminals use unscheduled communication e Yes Use lt 4 terminals per controller e No Use the number of terminals that you need Set aside connections for each PanelView Plus or VersaView CE terminal In this module Set asid
40. module in the chassis and set the revision to 7 12 3 6 1 0 Configuration 6 1756 Backplane 1756 410 0 1756 CNB D Local_CNB 5 ControlNet f 1 1756 ENBT A Local_ENBT 4 Sas Ethernet Module Properties Local 0 1 56 CNB D 7 12 General Connection ASNetWors Module Info Backplane Type 1756 CNB D 1756 ControlNet Bridge Vendor Allen Bradley Name Local_CNB Description Ee If you can t select the new revision then change the electronic keying to either compatible keying or disable keying Electronic Keying Ic Maintain and Troubleshoot the System 147 Action Details 12 Download the project to the secondary Important If 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 Do not abort a system lock Otherwise you ll clear the project from the secondary controller A Open the SRM configuration tool for the primary chassis B Click System Update 1757 SRM REDUNDANCY MODULE
41. network e update the schedule of an existing network e check the keepers e save the project for each controller Schedule a New Network 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 the following parameters In this box Specify Network Update Time Repetitive time interval in which data is sent over the ControlNet network Max Scheduled Address Greatest node number to use scheduled communications on the network Max Unscheduled Address Greatest node number that you will use on the network Media Redundancy Channels in use Network Name 10 11 12 13 Name for the network Choose OK From the Network menu choose Single Pass Browse From the File menu choose Save Type a name for the file that stores the network configuration then choose Save Select the Optimize and rewrite Schedule for all Connections button default and choose OK Publication 1756 UM523F EN P September 2006 100 Configure and Program the Controller Update the Schedule of an Existing Network 8 Turn on the power to each chassis Start RSNetworx for ControlNet software From the File menu choose Open Select the file
42. node addresses in the system to the CNB modules in the redundant chassis ControlLogix5563 then only 1 controller in EACH 1757 SRM module redundant chassis e Enough memory for 2 copies of all data e Only 1 in each redundant chassis e 7 connections for redundancy wy uses 2 slots NEVE Te s T Redundant e ININ R Chassis A e IB B M No i modules e T LL p Same size of chassis e Same slot number e Same catalog number series and revision i e Same memory size controller pp L JE C S Redundant e NJN N 0 i modules Chassis B B 1 e 1757 SRCx cable e 1 3 10 50 and 100 meter lengths Publication 1756 UM523F EN P September 2006 32 Design the System Place the Pair of Redundant With the standard redundancy module cables a pair of redundant Chassis chassis primary and secondary can function up to 100 meters apart p _ LIE C S Redundant e IN IN R Chassis A e g g m Noother modules T Redundancy Module Cable gt eS m e 1757 SRC1 cable 1 meter e 1757 SRC3 cable 3 meters e 1757 SRC10 cable 10 meters X e 1757 SRC50 cable 50 meters e 1757 SRC100 cable 100 meters pp L JE IC S Redundant e NIN R N o other modules Chassis B z B
43. 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 6 Synchronize the chassis A Go to the SRM configuration tool ow Set the Auto Synchronization option to the desired option C Synchronize the chassis Publication 1756 UM523F EN P September 2006 140 Maintain and Troubleshoot the System Update a Module Action 1 Upload and save the project Complete the following procedure to upgrade the revision of your redundant modules This procedure minimizes the time your process is down during an upgrade IMPORTANT Don t connect your computer to the network access port ona CNB module in the primary chassis You ll lose access to the network when you turn off power to the chassis Details A 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 B B Upload the project in the primary controller C Save the project 2 Open the SRM configuration tool for the secondary chassis Publication 1756 UM523F EN P September 2006 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 choo
44. 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 September 2006 180 If You Have Series B ControlNet Bridge Modules Notes Publication 1756 UM523F EN P September 2006 Appendix E Proper Use of an Ethe Don t rNet IP Network Restriction use ControlLogix5564 controllers Redundant System Restrictions For EtherNet IP communication and messaging keep the following restrictions in mind IMPORTANT Ina redundant system use an EtherNet IP network only for HMI workstation communication and messaging Do not use an EtherNet IP network for e communication with 1 0 modules e communication between devices via produced consumed tags Details You can t use this revision with 1756 L64 controllers Don t chassi use 1756 CN2 modules in a redundant s You can t use this revision with 1756 CN2 ControlNet bridge modules in a redundant chassis Don t use equipment phases This revision won t let you download a project that has equipment phases or create equipment phases online Don t use this revision to update a revision 11 or earlier system Use this revision only if your redundant chassis are alr
45. p dates 4 112 Interpret the SRM Event Log js oi acest aaaea 113 PUPP OSC aise in a a A He Sed ee er aa ced A 113 WHE Ate bebo a ee ea Be tae hee 2h eee eS as 113 Before You Begin a a5 uaaa ee O15 Pk S este amp Ree Gae es 113 INCTIOMIS A pen o a Bees pA Ranh erase WR Dea teak ce tok 114 Interpret SRM events 0 000000 0c 117 Export the SRM Event Log sien kod a ead da bea wentae 119 RULED OSE sf attei dose cen rae tuted fe th dts ter ot ol e E g tabs dane te 119 WII aa E ag NAP IS Gp te E RA ES Gad ie 119 Before You Begin 6 4 4 beta ad Ag Yigal hp ee Bes OE 119 a deh aan Teeth ee a inte in sill Geta tg gs Un ieee need 120 ACHONS Vi ek Goe Deeb Ge Oe tea ew deka hd amp eae a 120 Manually Synchronize the Chassis 4 122 Optimize Communication oaaae 123 Choose a Greater System Overhead Time Slice 124 Enter a System Overhead Time Slice 125 Make All Your Tasks Periodic 000 126 Check the Allocation of Unused Memory 127 Adjust GNE Usates ea aoiu aoei i e O E D aoa eam 127 Set Up EtherNet IP Communication Across Subnets Convert an Existing System to Redundancy Attributes of the Redundancy Object Table of Contents 9 Use RSLinx Software nauau aaau aaa 128 Look at the Four Character Display 128 Send a Message to the CNB Module 130 Change CNB modules from Series D to Series E 131 Before You Begin x Sie
46. the edits This happens even if you set the Advanced Redundancy Configuration gt xj controller to untest edits on a switchover IT Retain Test Edits on Switchover E Memory Usage Decide How You Want to Set Aside Unused Memory We recommend that you leave the Memory Usage slider in the middle default Advanced Redundancy Configuration S x I 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 Reserve more _ p memory for online addition of Tags Logic When the secondary controller receives crossload data it first buffers tag data in a quarantine section of memory When it has all of the data and knows it is valid it moves the data into the main memory area That is why a redundant controller requires twice as much memory for tags as a nonredundant controller Publication 1756 UM523F EN P September 2006 72 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 c logic If you plan to While online create roughly the same amount of new tags and
47. this tab For this item Configure and Program the Controller 97 Type or select Configuration Message Type CIP Generic Service Code Ac Class name bf Instance name 1 Attribute name Leave blank Source DINT tag with a value of 1 Num Of Elements 4 Destination Leave blank Communication Path 1 slot_ number where slot_number is the left hand slot number of the 1757 SRM module Connected check box Leave the Connected check box clear unchecked You can send only unconnected messages to a 1757 SRM module Set the clock of the SRM module Configuration Message Type CIP Generic Service Code 10 Class name 8b Instance name 1 Attribute name 1 Source WallClockTime 0 where WallClockTime isa DINT 2 array that stores the CurrentValue of the WALLCLOCKTIME object Num Of Elements 8 Destination Leave blank Communication Path 1 slot_ number Connected check box where slot_number is the 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 Publication 1756 UM523F EN P September 2006 98 Configure and Program the Controller Download the Project tothe You only have to download the project to the primary controller When the secondary controller is synchronized the system Primary Controller automatical
48. 04 3 Type Local 4 Type the name of the CNB module that is in the remote chassis 5 Select All Routines 6 Choose Find Within gt gt Find Within _ lt qe z ee Function Block Diagrams Ladder Diagrams lt lt Find Within Components Options Function Block Diagrams Ladder Diagrams Clinstruction Main Operand Comments Instruction Operands lt g jInstructions MRung Comments Rung Types 42805 7 Select Ladder Diagram 8 Check Instruction Operands 9 Choose Replace All The Search Results tab displays the changes to the logic Publication 1756 UM523F EN P September 2006 168 Convert an Existing System to Redundancy 10 Choose Close The following 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 OTE Operand 0 OTE Local 2 0 Data 0 Replaced Rung 1 XIC Operand 0 XIC Local 16 Data 1 Replaced Rung 1 OTE Operand 0 OTE Local 2 0 Data 1 Replaced Rung 2 XIC Operand 0 XIC Local 16 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 I 0 Tags Are any tags
49. 1 12 1996 23 10 06 070 Success 31 12 1971 23 00 00 000 Not attempted A Z zZ zZ gm The other chassis is now the primary chassis C 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 l secondary chassis You ve already updated the SRM module in this chassis 16 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 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log Syster Options uto Synchronization v SAMS erial Number C Choose Apply and Yes D Change the Date and Time in the SRM module E Choose OK Publication 1756 UM523F EN P September 2006 Appendix A Set Up EtherNet IP Communication Across Subnets Purpose of This Chapter To keep HMIs and messages pointing to the primary chassis when IP swapping is not in use When to Use This Chapter Use this chapter when e you want to use alias topics instead of IP swapping e your primary and secondary chassis are on different EtherNet IP subnets If both redundant chassis are on Different subnets Then You must point your HMIs and messages to t
50. 53 140 firmware combinations redundant system 14 G Get System Value instruction 90 171 GSV instruction 90 171 H HMI configure tags 76 design guidelines 30 34 optimize communication 123 switch between topics 149 Publication 1756 UM523F EN P September 2006 1 0 configure 74 convert local to remote 165 placement 21 33 51 redundant power supplies 36 import event log 119 inhibit a task 20 install system components 45 IP address assign 52 IP swapping 40 manage without IP swapping 149 what happens during a switchover 20 IP swapping overview 20 K keeper signature check 100 update 110 L load project from nonvolatile memory 137 message configure 76 instruction 76 send to SRM module 94 Microsoft Excel import event log 119 motion 20 MSG instruction 76 NAP 16 network access port restrictions 16 network update time guidelines 37 nonvolatile memory load a project 137 store a project 137 0 online edits during a switchover 18 finalize 71 plan for 69 operator interface design guidelines 34 P PanelView terminal design guidelines 30 34 periodic task 126 power supplies redundant 36 primary chassis assign a chassis as primary 15 produced tag configure 74 program finalize online edits 71 number of 79 program scan time estimate crossload time 77 minimize 79 overview 18 project create and maintain 69 download 98 edit online 18 load 137 store 137 project storage storing while
51. 55 Check the Revision of Your SRM Configuration Tool 57 Check the Version of Your SRM Configuration Tool 59 Set the Clock of the SRM 61 Test a Switchover 63 You want to change how the SRM Change the Auto Synchronization Option 65 supporis your system Change the Program Control Option 66 Both redundancy chassis lost power Set the Clock of the SRM 61 Open the SRM Purpose Configuration Tool To open the 1757 SRM System Redundancy Module configuration tool When Complete this procedure to e set the SRM clock Publication 1756 UM523F EN P September 2006 56 Configure the System Redundancy Module e test a switchover e troubleshoot a system e store or load a project using nonvolatile memory e update firmware 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 it for the first time e The revision of tool that you get depends on your version of RSLinx software e Some revisions of the SRM configuration tool aren t 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 F Workstation m Linx Gateways Ethernet Backplane 1756 Ax xx
52. 57 SRM 14 Chassis Redundancy State changed State Change 743353 11 30 2004 14 27 18 129 2 1756 EWEB 4A Entered Qualification Phase 4 State Change 743352 11 30 2004 14 27 18 066 5 1757 SRM 2E Qualification Complete Qualification 743351 11 30 2004 14 27 18 049 2 1756 EWEB 46 Entered Qualification Phase 3 State Change 743350 11 30 2004 14 27 17 045 2 1756 EWEB 3E Entered Qualification Phase 2 State Change 743349 11 30 2004 14 27 15 563 2 1756 EWEB 39 Entered Qualification Phase 1 State Change 743548 1123072004 14 77 155AN A 1757 SRM 2D Qualification Attemnted Qualification Chassis Event Log Time Module Description Classification 5456 11 30 2004 14 26 13 276 5 1757 SRM 2B Module Removal Starts Stops 5455 11 30 2004 14 26 13 148 5 1757 SRM 30 Switchover Attempted Switchover 5454 11 30 2004 14 26 13 ha 5 1757 SAM 45 SYS_FAIL_L Active Failure 11 30 2004 14 Tea 5 0 Transition to Lonely 0 5452 11 30 2004 11 28 26 E 2 1756 EWEE 69 Equally Able To Control State Change 5451 11 30 2004 11 28 26 564 5 1757 SRM 14 Chassis Redundancy State changed State Change Publication 1756 UM523F EN P September 2006 116 Maintain and Troubleshoot the System Actions 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 re done to close the Extended Information Definition dialog Example Exte
53. A controller has a major fault SRM OS Error The SRM has a problem SRM Serial Number Rule A check to choose a primary chassis if both chassis power up at the same time This is the final tie breaker The SRM with the lower serial number gets the first chance to become primary It becomes primary as long as the other chassis isn t more able to control the system Standby Secondaries Rule 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 tie SYS_FAIL_L Active 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 If you see a SYS_FAIL_L Inactive event within a few hundred milliseconds then a cable i
54. Chassis_A Add gt Chassis_B z SUMET A lt Remove 4 Select check the Switch on command check box Clear uncheck the remaining check boxes F isaehon ance Becc IV Switch on command Zen Gne This lets the ControlLogix Redundancy Alias Topic Switcher software control which topic the T Update all Topics alias topic uses for communication 5 Choose and then Publication 1756 UM523F EN P September 2006 Set Up EtherNet IP Communication Across Subnets 155 Set Up the Alias Topic Switcher IMPORTANT If you start the Alias Topic Switcher software without access to an RSLinx activation file for example without a version of RSLinx which supports OPC the following error occurs 0x80040112 The text for the message depends on your operating system 2 2 HUSH EODA aBan aS 1 In the system tray right click the Redundancy Switch icon and choose Open Alias Topic Switching Tool 2 Inthe Redundancy Alias Topic Switching Too window choose gi B RSLinx Alias Topic Alias_Topic_1 OD _ RSLinx OPC Topic for Chassis 4 Topic_Chassis_A B RSLinx OPC Topic for Chassis B Topic_Chassis_B 3 Type the topic names a Alias topic Topic Currently Used by Alias Topic Chassis 4 Redundancy State Unknown b Topic for the controller in Chassis A Chassis B Redundancy State Unknown i Redundancy Alias Topic Switching Tool a E oj x RSLinx Alias Topic _ Chassis A Topic Chassis B
55. 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 safe packaging Install the Chassis for the Controllers 42798 1 Install 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 IN080 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 September 2006 48 Install the System 2 For each chassis install a ControlLogix power supply according to the corresponding installation instructions Install this power supply According to this publication 1756 PA72 ControlLogix Power Supplies Installation Instruction
56. F watchdog ms I Disable Automatic Output Processing To Reduce Task Overhead Inhibit Task C Type a watchdog time that is more than the watchdog time from step 1 D Choose OK Cancel Apply Help Publication 1756 UM523F EN P September 2006 Configure and Program the Controller 103 Action Details 3 Determine the real scan time of a task Do the following steps while the controller is running m Controller Primary Tasks fF MainTask A Right click the task and choose Properties B Click Monitor E Task Properties MainTask General Configuration Program Schedule Monitor Look at the scan times c Scan Times Elapsed Time Heset Max l ms Longest time it s 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 Min l ms Task Overlap Count E Choose OK Cancel 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 100 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 September 2006 104 Configure and Progra
57. F EN P September 2006 Before You Begin eG ich cette oboe g Sph Gedsia a GU wee Uoinbtse Sp 95 PMCS eeen Oe eG deep ik Ua Are EP re Rk tase wih oe Mey ES 96 Download the Project to the Primary Controller 98 Schedule the ControlNet Networks 04 98 Schedule a New Network 0 0 000 000 eee 99 Update the Schedule of an Existing Network 100 Check the Iceperss say 2y gow SOAs AE OM ES EEG 100 Save the Project for Each Controller 46 004 06404 101 Ser the Task Watchdog Times cat naana eat honed 102 Chapter 6 When to Use This Chapter asa falas Sat eed 105 How to Use This Chapter naaa a aana 105 Find the Cause of a Switchover or Disqualification 106 PER POS CS Aes m rao ae tah laced kek ag rine eee tee Me et 106 Wk 48 ECA he Rh Paw Seas Be Fe BREN Ee 106 SPST hice eoa e Seen fp Oude Hae Gite oh Nard od Petes 106 Troubleshoot a Failure to Synchronize 108 Update a Keeper Signature in 5 5 tas aot Bee SSR 110 PUTDOSE ka pet Fed Galatta ae ade a ROE Gb Quand we meat ae 110 When Rt 4 a eile ast onal gt Me duces Revers lee QAR dM en nn Bean 110 Before You Begin osx favs Biase ek ek oe A tht Be he 110 ACHONS Sconce a a a eee seas eee Maren le Brana 110 See if an Edit Session Is in Progress 00 111 BUPpOSCs T nuod m mas 2108S tua Oakes bbe Ga Ah feck ade Gace 111 WSO ake pia Soe ae Rte he BONS OSE ATO ate ee 111 ACUIONS repa a pn a a say a a Wa e pip Goebel bee
58. M e If You 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 1 Keep total light loss through the cable less than or equal to 7dB 2 Keep total length less than or equal to 4 km 3 Use high quality 62 5 125 micron multi mode fiber optic cable 4 Use professionally installed SC style connectors to connect to the 1757 SRM modules Publication 1756 UM523F EN P September 2006 Design the System 33 Place the 0 In a ControlLogix redundancy system place all I O in ONLY the following 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 H i o Redundant chassis pair li Ei C DIDI C E ControlNet network cs N 0 modules HININEIN Remote chassis B R B BI B X 1 0 No ke Loo eee m EtherNet IP network HMI Yes cava ate X 1 0 No ControlNet network L HMI Yes 0 Yes DeviceNet network HMI Yes 0 Yes Universal remote I O network HMI Yes Publication 1756 UM523F EN P September 2006 34 Design the System Place Operator Interface For operator
59. Module Info Configuration Synchronization Synchror Move Identification Size Minimize OK Vendor Rockwell Automation El weenie Allen Bradley 2 X Close Alt F4 None Product Type Redundancy Product About None b Trae 1 B Right click the title bar of the configuration tool and choose About Publication 1756 UM523F EN P September 2006 Set the Clock of the SRM Action 1 Open the SRM configuration tool for the primary chassis Configure the System Redundancy Module 61 Purpose To set clock of the 1757 SRM module When Perform this procedure e after system installation e after power loss to both chassis Before You Begin The SRM clock records when significant events occur Please note the following 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 doesn t 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 S
60. N P September 2006 174 Attributes of the Redundancy Object For this information Get this attribute Data GSV SSV Description type Slot number of the SRMSlotNumber INT GSV 1757 SRM module in this chassis e Size of the last crossload LastDataTransfer DINT GSV This attribute gives the size of data that was or would have e Size ofthe lastcrossload Sie been crossloaded in the last scan if you had d ioe P SORAR N e The size in DINTs 4 byte words e You must configure the controller for redundancy e You don t 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 MaxDataTransfer DINT GSV This attribute gives the biggest size of the LastData Transfer crossload Size Size attribute e Size of the biggest SSV crossload if you had a secondary chassis Publication 1756 UM523F EN P September 2006 e The size in DINTs 4 byte words e You must configure the controller for redundancy e You don t 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 About This Appendix Communication Loss if You Br
61. NAP use a remote 0 node HF gt ia Other networks At least 2 nodes in addition to the CNBs in a the redundant chassis An additional node can be y h e a second CNB module in the same remote chassis or in a different remote chassis A e any other ControlNet device not required to be keeper capable Publication 1756 UM523F EN P September 2006 Design the System 31 1756 ENBT or 1756 EWEB modules ControlLogix Redundancy Requirements and Recommendations Continued 1 2 in each redundant chassis total communication modules CNBs and ENBTs in each redundant chassis For 1756 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 41 00 Build 10 6 or later ControlLogix5555 ControlLogix5561 ControlLogix5562 or ControlLogix5563 controllers Same type of controller throughout the chassis If ControlLogix5555 then 1 or 2 controllers in EACH redundant chassis If ControlLogix5561 ControlLogix5562 or BE 1756 CNB D E or 1756 CNBR D E module or modules e 1 5 in each redundant chassis e lt S total communication modules CNBs ENBTs and EWEBs in each redundant chassis e Keep CPU usage lt 5 e Allocate 2 consecutive node addresses for each set of partner CNB modules one in each chassis e Assign each partner CNB module to the same node address e Assign the higher
62. O configuration folder of the controller This type of communication Is Update 1 0 data not including block transfers Scheduled communication Produce or consume tags Communicate with programming devices 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 1 0 connections such as Removal and Insertion Under Power conditions this does not include normal I O updates that occur during the execution of logic Bridge communications from the serial port of the controller to other ControlLogix devices via the ControlLogix backplane Publication 1756 UM523F EN P September 2006 124 Maintain and Troubleshoot the System To speed up unscheduled communication If an RSLogix 5000 project contains Then See Page Only a continuous task and no other tasks Choose a Greater System Overhead Time 124 This is the default task configuration Slice More than one task for example at least 1 Make All Your Tasks Periodic 126 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 comm
63. OOLs are together Members Data Type Size 12 byte s ee Bool_1 BOOL ae Bool_2 BOOL Decimal Bool_3 BOOL Decimal Dint_1 DINT Decimal Dint_2 DINT Decimal Than this This data type takes 20 bytes The BOOLs are spread out Members Data Type Size 20 byte s es Style Description Dint_1 S WT Decimal Bool_2 BOOL Decimal Dint_2 DINT Decimal Bool_3 BOOL Decimal Publication 1756 UM523F EN P September 2006 82 Configure and Program the Controller Action Details 6 Keep code as compact as possible Avoid checking the same conditions many times Each instruction adds scan time to your controller This is better This rung checks Boo _B and Bool_C only once each scan Bool_A MSG Type CIP Data Table Write Message Control MSG_1 17 MSG Type CIP Data Table Write Message Control MSG_2 i i Than this This rung checks Boo _B and Bool _C twice each scan One or two instructions don t 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 E 17 MSG Type CIP Data Table Write Message Control MSG_2 17 Publication 1756 UM523F EN P September 2006 Configure and Program the Controller 83 Action Details 7 Execute code only when you need it The controller crossloads a tag anytim
64. RSView 32 software e Any other HMI client software that uses RSLinx 2 x software 2 ControlNet network e PanelView Standard terminal Do terminals use unscheduled 30 34 37 PanelView 1000e 1400e terminal e PanelView Plus terminal e VersaView industrial computer running a Windows CE operating system communication e Yes Use lt A terminals per controller e No Use the number of terminals that you need Set aside connections for EACH PanelView Plus or VersaView CE terminal In this module Set aside controller 5 connections CNB 5 connections e RSView Supervisory Edition software e RSView 32 software e Any other HMI client software that uses RSLinx 2 x software Limit the number of RSLinx servers that a controller uses to 1 ideal to 3 maximum Publication 1756 UM523F EN P September 2006 26 ControlLogix Redundancy Overview Compatible Software With version 15 56 of the ControlLogix redundancy system use any of Versions For This Software Use This Version Notes RSLinx 2 50 the following software versions 1757 SRM System Redundancy 3 4 Important Don t update the SRM Configuration tool at this time See Module Configuration tool Update a System That Is Already at Revision 13 on page 142 Get Knowledgebase document G92234770 To access Rockwell Automation s Knowledgebase go to http support rockwellautomation com PanelView Plus terminal VersaView industrial computer
65. Redundancy Commands Sy B Choose Synchronize Secondary and then Yes C Wait for the chassis to synchronize C Chassis 4 Primary with Synchronized Secondary 4uto Synchronization State Never 11 Initiate a switchover 12 Replace the CNB modules in the new 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Update Redundancy Commands Choose nitiate Switchover and Yes Repeat steps 7 thru 9 for the CNB modules in the new secondary chassis secondary chassis Publication 1756 UM523F EN P September 2006 Maintain and Troubleshoot the System 137 Action 13 Synchronize the chassis Details A B On the Configuration tab change the Auto Synchronization option to Always Go to the SRM configuration tool for the primary chassis 1757 SRM REDUNDANCY MODULE C Module Info Configuration Synchronization Synchronization Status Event Log System Update Options Auto Synchronization v Name Choose Apply and Yes BM Serial Number 14 In the RSLogix 5000 project change the revision of the new local CNB modules to revision 11 Store or Load a Project Using Nonvolatile Memory E Module Properties Local 4 1756 CNBR E 11 1 Nonvolatile memory lets you keep a copy of your project on the General Connection RSNetWors Module Info Backplane Type 1756 CNBR E 1756 Contr
66. Sede Shp Cb pak eae de ed 77 CULO IS yea tat g SW ane SG chy toh i Aa he an ha A las ee te ha eS 78 Minimize Scan Time ec nk ha ik s soe 8 Ee DUNE Phar ee OS 79 Maintain the Integrity of Your Data During a Switchover 85 Look for Array Shift Instructions o a aoaaa aaa 87 Look for Scan Dependent Logic n naaasar a RS 87 Take Preventative Actions 4 94 6 34 45 8484 eey ho ah ey 88 Determine the Status of Your Redundancy System 90 BUTPOSC sited tote ok Reh ten hae RR A aaa eke ye tow E 90 WIG Kis 4 He An eR ORY ROOT EAD SARs ee Oe 90 ACHONS oa 145500 a ab ads aes e GER Re EARL bd BH Ord AMEE eg 90 Example 1 Ladder Diagram n a anaana Ge ak Gol tho 90 Example 2 Structured Text n a ota vai vera he Katee wines 90 Check Your Work wal ais 6 i acd eas urate ok parry nats 91 For More Information aasa aa ee ie ea ie hae hae 91 Condition Logic to Run After a Switchover 91 POMOS S48 Sah OS Fe REO OES EE MES As 91 When st ta tao ened a Oa ace ade ae eee le aoe 92 Example 1 Ladder Diagram n n anaana ded ae ts 6 92 Example 2 Structured Text oaan ow auineinwoes 93 Send a Message to the SRM 0 fed s 0055 8 402 ew bee a Sa es 94 PUT POSE x ope ied Ue ere eae eis Gis ie le O ade Aide Salk week el 94 WIER hss ai a E E Bel oky vate Rte lek tot adap Behan es 94 Publication 1756 UM523F EN P September 2006 8 Table of Contents Maintain and Troubleshoot the System Publication 1756 UM523
67. Synchronization Synchronization Status Event Log Commands Synchronize Secondary Disquality Secondary Initiate Switchover 6 Become Eiman 6 Choose Synchronize Secondary and then choose Yes to confirm 7 Choose OK Publication 1756 UM523F EN P September 2006 Front panel ControINET Look here Hp j at ay i Maintain and Troubleshoot the System 123 8 In the primary chassis what do the CNB modules display lf you see Which means Then PwOg Primary with Synchronizing Synchronization is in progress Qualifying Secondary e Continue waiting It may take several minutes to synchronize the secondary chassis Ol a Optimize Communication 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 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 108 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
68. 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 Different subnets Primary chassis Router Switch Switch Secondary chassis You MUST change to the new primary address after a switchover Use ControlLogix Redundancy Alias Topic Switcher software to do this See Appendix A 6 If you re using IP swapping give the same IP address to the primary module and its partner Pair of ENBT or EWEB modules one in each redundant chassis 1st pair of ENBT or EWEB modules A Give the SAME IP 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 modules to Leave this open for the secondary 10 10 10 10 10 10 10 11 The module in the secondary chassis automatically uses the IP address of the primary 1 Worksheet for IP Swapping Slot Configuration Primary IP address Secondary IP address primary address 1 Subnet mask Gateway address 2nd pair of ENBT or EWEB modules Publication 1756 UM523F EN P September 2006 42 Design the System One switch One subnet Several switches Several subnets Publication 1756 UM523F EN P September 2006
69. aana oan aae 55 How to Use this Chapter nannaa saaa 55 Open the SRM Configuration TOO such wa 4 saaa aaas 55 PUDOSCS tet E anny ana een E een ye Rama aimee 55 NW DICH ear jae Novag ae n su ga eter AMEE GIA Nn 8 a CEB Gee 55 Before You Begin 6 0 oii so Rod meren Bech OE EP mate 56 ACHONS A 5 Siar BE ont hha elas he aot et Seale Ms Se at eg Sk ain 56 Wh t to Do Net att atte te 2a oleh ew ea eens aed 57 Check the Revision of Your SRM Configuration Tool 57 PUP POSS S ynn i aa pe hg E Oe a a a a Se hth a hh 57 WCU te ate stats Yate dete le ate Mp hee BLUSH ae 58 Before You Begin ta suscesn re popes hd 9 ae 8 Sendo GS 8 Be 4G le ee 58 ACHONS hae g e cae Yas de Gee Sate ce se ae dese Sf che sp ask arb si 59 Check the Version of the Configuration Tool 59 PULDOSE 444 4 eerie eS POSES ees BS Fa 8 SSPE RES BOS 59 do Re Se ee aE Ree ee Eee ere a eee re 59 AGHONS sais atest ak fous a Baek hte nee eo a 60 Set the Clock of the SRM eee Boros Ue Keeee Shes 61 PU DOS Gore s usra se aa a a A hee et Ei ae EA a g 61 When ena ga ese Sisk had aa fae 2 oo Gia E oa Ba Sp Quek oa tan 61 Before You Begi Aroana wins Bea esa se Karan eas 61 NCUONS 4 2 pote A p apes PEND REN od 61 Testa Switehovet vers tote i ieee ea ee bP net 63 Purposes rpne a aC ON en rea eT ie ree an ene 63 ANGI ax send Matisse ahaa ahr tn doe atern ds whack aan Seth 63 Before You Begin 6 y0 ot 63660 Fee teveeutt edd 63 NOMONS yo a Be ce het Sp cea elt pe ds Ah
70. ash the Modules 53 Check Your Installation 53 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 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 September 2006 46 Install the System Install this component 1756 A4 A7 A10 A13 or A17 chassis This chapter provides the sequence of tasks and the critical actions for the successful installation of a ControlLogix redundancy system It does not replace the installation instructions for the components of the system During installation refer to the following publications According to this publication ControlLogix Chassis Installation Instructions publication 1756 INO80 1756 PA72 or PB72 power supply 1756 PA75 or PB75 power supply ControlLogix Power Supplies Installation Instructions publication 1756 5 67 Cont
71. ask 1 is significantly less than its period 20 ms is less than 80 ms 2 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 September 2006 Maintain and Troubleshoot the System 127 Check the Allocation of The ee Hae a specific cae se its unused P for tags and the rest for logic Depending on how you configure the Unused Memory memory usage you might not have memory for the required operation To display this dialog box Advanced Redundancy Configuration 1 Choose Edit Controller Properties Retain Test Edits on Switchover 2 On the Redundancy tab choose the Advanced button Tertii 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 gt memory for online addition of Tags Logic j lf Then Important You are unable to perform online edits OPC communications error or fail Make sure the slider is not a
72. assis 7 Synchronize the chassis A Go to the SRM configuration tool 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Update Redundancy Commands B Choose Synchronize Secondary and then Yes The chassis are synchronized Chassis 4 Primary with Synchronized Secondary Auto Synchronization State Never o j Publication 1756 UM523F EN P September 2006 Maintain and Troubleshoot the System 145 Action Details 8 Initiate a switchover 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Update Initiate Switchover D E es Redundancy Commands A Choose nitiate Switchover and Yes B Wait for the system to switchover The other chassis is now the primary chassis C Chassis B Primary with Disqualified Secondary 4uto Synchronization State Never 9 Update the modules in the new Use the ControlFLASH firmware update tool to update the modules in the new secondary secondary chassis chassis 10 Prepare the RSLogix 5000 project for the A Start RSLogix 5000 software and go online to the primary controller update 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 i
73. blication 1756 UM523F EN P September 2006 Configure the System Redundancy Module 67 Action 1 Open the SRM configuration tool for the primary chassis Actions Details A Start RSLinx software 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 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log Identification Status Vendor Rockwell Automation Baral zls Allen Bradley Major Fault None Product Type Redundancy Product 2 Set the program control option A Click Configuration B Do you want to let a controller send a message to the SRM e Yes Check the Enable User Program Control check box e No Uncheck the Enable User Program Control check box 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log Options Auto Synchronization Aways 7 SRM Serial Number Name Description Chassis ID Chassis B 7 Location Enable User Program Control C Choose Apply and then Yes to continue D Choose OK Publication 1756 UM523F EN P September 2006 68 Configure the System Redundancy Module Notes Publication 1756 UM523F EN P September 2006 When to Use This Chapter How to Use This Chapter Plan for Online Edits
74. cal I O modules e replace local I O tags e replace any aliases to local I O tags Publication 1756 UM523F EN P September 2006 166 Convert an Existing System to Redundancy Reconfigure the Local 1 0 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 UM001 F 1 0 Configuration x 1756 xxx name_of_local_module lt q Cut local 1 0 modules from here x 1756 CNB x name_of_local_CNB z x 1756 CNB x name_of_remote_CNB lt q Paste the 1 0 modules here 2 In the controller organizer cut the modules from the local I O configuration and paste them into the remote CNB module Cut and paste the following modules e I O e 1756 DHRIO e 1750 DNB 1756 ENET or ENB e 1756 MVI Replace Local 1 0 Tags 1 Open a routine If a routine is already open click within the routine to activate the window 2 Press the Ctrl H keys Publication 1756 UM523F EN P September 2006 Convert an Existing System to Redundancy 167 Replace in Routines x 3 gt Find What x z v Test Only Email 4 Replace with x zj Replace Replace All 5 Bee AI Routines al Close M Wrap Direction el elp I Match Whole Word Only C Up Down ea ete Find Within gt 6 Function Block Diagrams Ladder Diagrams 428
75. chronize the secondary chassis Publication 1756 UM523F EN P September 2006 184 Redundant System Restrictions Restriction Details If you unplug the fiber optic cable between If you unplug the fiber optic cable between the 1757 SRM modules check the the SRM modules wait until they stabilize synchronization status of the secondary SRM module before you reconnect the cable Wait before you reconnect It until its status is secondary with no partner You can reconnect the cable once the module is in that state Otherwise the secondary SRM could fault with EA91 error Publication 1756 UM523F EN P September 2006 Numerics 1756 ENBT module See ENBT module 1756 EWEB module EWEB module 1756 HYD02 20 1756 L60MO03SE 21 1756 M02AE 21 1756 M02AS 21 1756 M03SE 21 1756 M08SE 21 1756 M16SE 21 1757 SRC cable lengths 32 1757 SRM module See SRM module A auto synchronization 65 BSL instruction 85 BSR instruction 85 C change CNB modules from series D to series E 131 chassis assign a chassis as primary 15 install 47 clock SRM module 61 94 CNB module 4 character display 128 addresses during a switchover 19 connection 37 install 48 requirements 22 31 statistics 127 usage 127 CNB modules changing from series D to series E 131 communication optimize 123 compatible software versions redundant system 26 configure controller 72 Index EtherNet IP module 52 1 0 74 SRM module 55 connection 37 consumed tag conf
76. cs Together they keep your HMI communicating with the primary controller after a switchover Primary Chassis firmware XXXX XX 012345 E EE RSLinx we software f Alias Topic Wel e 4 Topic for Chassis A Topic for Chassis B ol A i B Chassis A Publication 1756 UM523F EN P September 2006 E N B Chassis B 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 represents a flexible communication path to one of several controllers topics e In 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 Topic In RSLinx software a topic represents a specific path to a controller Since each ENBT and EWEB module uses a unique IP address create a topic for the controller in each redundant chassis Set Up EtherNet IP Communication Across Subnets 151 To
77. cted check Publication 1756 UM523F EN P September 2006 96 Configure and Program the Controller Actions Use the following table to configure a message to an SRM module Configuring a Message to an SRM If you want to initiate a switchover On this tab For this item Type or select Configuration Message Type CIP Generic Service Code 4e Class name bf Instance name 1 Attribute name leave blank Source DINT tag with a value of 1 Num Of Elements 4 Destination leave blank Communication Path 1 slot_ number where slot_number is the left hand slot number of the 1757 SRM module Connected check box Leave the Connected check box clear unchecked You can send only unconnected messages to a 1757 SRM module Disqualify the secondary controller Configuration Message Type CIP Generic Service Code Ad Class name bf Instance name 1 Attribute name Leave blank Source DINT tag with a value of 1 Num Of Elements 4 Destination Leave blank Communication Path 1 slot_ number Publication 1756 UM523F EN P September 2006 where slot number is the left hand slot number of the 1757 SRM module Connected check box Leave the Connected check box clear unchecked You can send only unconnected messages to a 1757 SRM module Configuring a Message to an SRM Continued If you want to Synchronize the secondary controller On
78. d 165 Convert Local Modules to Remote Modules 165 Reconfigure the Local I O Modules 166 Replace Local I O Tags aso aia tela al aly Bah 220 ayy Uh ghee BUR 166 Replace Any Aliases to Local I O Tags 168 Appendix C gr Lh eral aes pie Ga a a gems gee Bas pared ase geet nak dy seek ote dete ates a Seo a Sante 4 171 Publication 1756 UM523F EN P September 2006 10 Table of Contents If You Have Series B ControlNet Bridge Modules Redundant System Restrictions Publication 1756 UM523F EN P September 2006 Appendix D ADOUE This Appendix sa esad ane ede e eA E 175 Communication Loss If You Bridge Through a Series B ControlNet Bridge Module a gay ak Be Ree ee Hak YE 175 Situation 52 2 uae edad dowd Be bok Seth alee he AAA a oe 175 Prevento ea a eanna a na a a aE 176 Communication Could Stop If You Use a Series B ControlNet B idge Mod le fo ia i550 gah sting Ad ot nia Boek nee Sew wt 177 Situation p68 SER Ys Fe EAS SOE DEY Pek CL ORS Sed 177 COMECIVE ACHON 30 9 ata haat a a sien aD Aw RADA i 177 Prevento Gl ok oo t a aa a E i s ae 177 Appendix E Proper Use of an EtherNet IP Network 181 Purpose of this Manual Who Should Use this Manual When to Use This Manual How to Use this Manual Preface This manual guides the design development and implementation of a redundancy system for a ControlLogix controller This manual is intended for those in the follo
79. declared from within the expression of an FSC instruction e fault cleared by user fault routine Lgx00055522 An SLC typed write message to a redundant controller produced error F007 Lgx00058402 Memory changes during prescan weren t always crossloaded Sometimes the primary controller didn t send data changes that it made during prescan to the secondary controller Lgx00060517 Some data table write services weren t immediately forwarded to the secondary controller A secondary SRM faulted with an E888 error if you unplugged a CNB module Data table write big write and read modify write services weren t immediately forwarded to the secondary controller if the service used a symbolic address Instead they were forwarded after the next program scan Lgx00060643 The secondary 1757 SRM module sometimes faulted while synchronized if you unplugged the tap to a secondary 1756 CNB module The error code of the SRM module was E888 This caused the chassis to become disqualified You had to remove and reinsert the secondary SRM module under power to recover Lgx00060989 A synchronized chassis pair didn t automatically synchronize after being disqualified The redundant chassis pair didn t automatically synchronize after multiple cycles of disqualification caused by either unplugging the tap to a secondary 1756 CNB module or power cycling the secondary chassis You had to remove and reinsert the secondary SRM module unde
80. dules such as 1756 ENET 1756 DHRIO 1756 MVI 1756 DNB Publication 1756 UM523F EN P September 2006 52 Install the System Configure the EtherNet IP Modules Action 1 Before you begin To use an EtherNet IP module give it an IP address subnet mask and gateway address Details A Perform the following steps if you haven t already e Install and connect both 1757 SRM modules e Get the IP address subnet mask and gateway address for each EtherNet IP module See Plan the EtherNet IP Networks on page 12 oo Do you know how to configure an EtherNet IP module in a nonredundant system e Ifno then continue with step C e f yes then go to step 2 Get the following publication EtherNet IP Modules in Logix5000 Control Systems publication ENET UM001 You ll use that publication when you configure each module 2 Configure the EtherNet IP modules in the first chassis oo Turn on the power to only one of the redundant chassis For example if both chassis are on turn off one of them Configure the EtherNet IP module in the chassis that is on Do you see the IP address on the front of the module e fno then return to step B e f yes then continue with step D D Repeat steps 2B and 2C for each EtherNet IP module in this chassis 3 Configure the EtherNet IP modules in the second chassis Publication 1756 UM523F EN P September 2006 ive m Turn off the chassi
81. e controller 5 connections CNB 5 connections RSView Supervisory Edition software RSView 32 software Any other HMI client software that uses RSLinx 2 x software Publication 1756 UM523F EN P September 2006 Limit the number of RSLinx servers that a controller uses to 1 ideal to 3 maximum Design the System 35 Add Additional Redundant In addition to using redundant pairs of controllers you may also add Components the following 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 the following components e 1756 CNBR ControlNet modules e Two identical ControlNet links ControlLogix chassis with 1756 CNBR module ControlNet node Redundant media LL O S LE le les Ti h ControlNet node Publication 1756 UM523F EN P September 2006 36 Design the System Redundant Power Supplies Redundant power supplies let you maintain power to a ControlLogix chassis if a power supply fails Redundant power supplies use the following hardware e Two redundant power supplies any combination of 1756 PA75R and 1750 PB75R e 1756 PSCA chassis adapter module in place of the standard power supply e Two 1756
82. e 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 a rung false when you don t 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_Tag crossloads only when the ADD instruction produces a new value DD New _Data Add Source Tag_1 pe Source B Tag_2 0e Dest Dest_Tag De Than this The ADD instruction writes the sum of Jag_7 Tag_2to Dest_Tag each time the rung executes The controller crossloads Dest_ Tag every scan even if Tag_1 and Tag_2 stay the same DD Add Source Tag_1 o Source B Tag_2 0e Dest Dest_Tag 0e Publication 1756 UM523F EN P September 2006 84 Confi
83. eady updated to revision 13 or aren t in operation yet Don t use the nonvolatile memory of a ControlLogix5555 controller Don t use the nonvolatile memory of a 1756 L55M2x controller This includes storing a project to nonvolatile memory and loading it from nonvolatile memory Otherwise the controller will have an unrecoverable fault solid red OK light and clear the project from its memory Lgx00068091 Publication 1756 UM523F EN P September 2006 182 Redundant System Restrictions Details Restriction Always keep the controller unlocked Make sure the controller stays unlocked Revision 2 6 or later of the SRM configuration tool doesn t work with revision 11 or earlier systems Rem Run IY 3 Controller No Forces gt ene No Edits amp 22 m Don t lock the controller Rem Run TY 2 Control No Forces gt No Edits 2 A redundancy system automatically unlocks a locked controller during a switchover But the workstation that locked the controller doesn t show the change The workstation continues to show that the controller is locked even though it isn t Once the controller is unlocked multiple workstations can edit the project in the controller Lgx00067869 Revision 2 6 or later of the 1757 SRM System Redundancy Module Configuration tool doesn t work with revision 11 or earlier redundancy systems You can cause the 1757 SRM module to fault e Use revision 2 6 or later of the c
84. econdary chassis And each communication module in the primary chassis Has a matching partner in the secondary chassis And a secondary communication module hasa Red OK light Then Replace the module Green OK light Check the 1757 SRC cable for a proper connection Doesn t have a matching partner in the secondary chassis gt Install a matching module Doesn t have power gt Restore the power 4 Wait several minutes for the system to try to synchronize 5 What do the CNB modules in the primary chassis show e PWQS Stop Your system is synchronized e PwDS Go to step 6 6 Use the following table to troubleshoot the secondary chassis Ifthe SRM module And a secondary CNB And a secondary controller Then hasa module hasa Green OK LED Doesn t show NET ERR Flashing Red OK light Clear the major fault of the controller It s 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 7 Shows NET ERR gt Check all ControlNet taps connectors and terminators for proper connections Red OK LED gt 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
85. ed Total Controller Fault Handler lt none gt T Power Up Handler lt none gt bd 3 p System Overhead a Time Slice i 4 3 Type or select a value for the system overhead time slice 4 Choose Publication 1756 UM523F EN P September 2006 126 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 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 ha ha 2 Follow these guidelines to set the If you have multiple tasks make sure that periods of the tasks 1 The execution time of a highest priority task is significantly less than its period 2 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 Task Priority Execution time Rate 1 higher 20 ms 80 ms 2 lower 30 ms 100 ms total execution time 50 ms 1 The execution time of the highest priority task T
86. ee Interpret the SRM Event Log on page 10 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 Publication 1756 UM523F EN P September 2006 62 Configure the System Redundancy Module Action 2 Set the clock Details A Click Configuration 1757 SRM REDUNDANCY MODULE Aways E lChassisB rom amare x j a 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 Setand then Yes C Choose OK Publication 1756 UM523F EN P September 2006 Test a Switchover ControlNET Sr aoga at a i Ol a 43130 Action Configure the System Redundancy Module 63 Purpose To use RSLinx software to manually initiate a switchover When Perform this procedure after you ve synchronized your system and want to test a switchover Before You Begin The CNB modules in the new primary chassis show the synchronization progress after a switchover Typically the modules show the following sequence PwNS gt PwDS gt PwOg gt PwQS primary with no primary with primary with primary with secondary disqualified sy
87. eper information or e keeper signature that does not match the keeper signature of the network Av Active network keeper with e valid keeper information e keeper signature that defines the keeper signature of the network li Inactive network keeper with either e invalid keeper information or e keeper signature that does not match the keeper signature of the network lv Inactive network keeper with valid keeper information that matches the keeper signature of the network Oi e Powering up with invalid keeper information or e offline with invalid keeper information Ov e Powering up with valid keeper information that may or may not match the keeper signature of the network or e offline with valid keeper information that may or may not match the keeper signature of the network Number of times that the Bxnn nn is the number of times that the bandwidth of the module was exceeded bandwidth bandwidth of the module was exceeded exceeded error since the module was turned off or reset You see this number only if the number is more than zero Publication 1756 UM523F EN P September 2006 130 Maintain and Troubleshoot the System On this tab 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 as follows Type or select Configuration For this Message Type CIP Generic Service Type Custom Service Code Af Class al Instance 8
88. es gets the first chance to become primary It becomes primary as long as the other chassis isn t more able to control the system Chassis Redundancy State changed to The chassis changed to a different redundancy state e PwOS Primary with qualified synchronized secondary partner e OSwP Qualified synchronized secondary with primary partner e DSwP Disqualified secondary with primary partner DSwNP Disqualified secondary with no partner PwDS Primary with disqualified secondary partner e PwNS Primary with no secondary partner Crossloading Error A module isn t able to get some information to its partner Disqualified Secondaries Rule Failed Modules Rule 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 isn t faulted In that case the other chassis becomes primary Firmware Error The SRM has a problem Module Insertion 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
89. etRedundState_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 DN Chas4_GetRedundState_FromENBT EN Type CIP Generic Message Control Chas4_GetRedundState_FromENBT h gt Ro Tag Name Description Alias For Data Type Timer_RedundancyMSGs Periodic trigger for the execution of MSG TIMER instructions Triggers MSGs every 2s ChasA_GetRedundState_FromENBT Message instruction that gets the redundancy state MESSAGE of Chassis A ChasA_RedundancyState Redundancy state of the Chassis A DINT 2 PwOS 3 PwDS 4 PwNS MSG parameter 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 September 2006 Set Up EtherNet IP Communication Across Subnets 159 MSG parameter Value Source Length Destination ChasA_RedundancyState Path Specify the 1756 ENBT module in Chassis A Use either of the Communication tab following 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 Get the Redundancy State of Cha
90. f the tool with an revision 11 x or earlier redundancy systems Publication 1756 UM523F EN P September 2006 58 Configure the System Redundancy Module Publication 1756 UM523F EN P September 2006 When 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 the following table to see which revision of the tool that you get If you install Then you get RSLinx software revision 2 42 SRM configuration tool revision 2 5 RSLinx software revision 2 43 SRM configuration tool revision 2 6 Action 1 Choose which revision to use Configure the System Redundancy Module 59 Actions Details Do you connect your computer to ControlLogix redundancy systems revision 11 x or earlier e Yes Use revision 2 5 of the SRM Configuration Tool DONT 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 ll 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
91. 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 Than this Tasks E a MainTask E cs MainProgram A Program Tags EBI MainRoutine B Count_Reset B MDS_Alarms B MDS_PLC_Clock B MDS_Status B SCANTIME_MONITOR C3 ATR_Comms C3 HLCComms C3 ME_Comms cs Cony E r Publication 1756 UM523F EN P September 2006 80 Configure and Program the Controller Action Details 2 Delete unused tags 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 Sot TagN Description 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 Tag Name 7 Alias For Base Tag Type Bool_Array BOOL 32 The
92. g Primary Full lt empty gt _ lt empty gt lt empty gt 0 1757 SRM Disqualified Primary Full ONO Ne WMO 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 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log C Auto Synchronization ARSE SRM Serial Number e See Troubleshoot a Failure to Synchronize on page 5 Publication 1756 UM523F EN P September 2006 Change the Auto Synchronization Option Action 1 Decide when you want the system to synchronize Configure the System Redundancy Module 65 Purpose To change when the 1757 SRM module tries to synchronize the controllers When Perform this procedure to e help synchronize the system e prevent the system from crossloading changes Actions Details Do you plan to manually disqualify a chassis so you can make changes e No Choose Always e Yes Choose Conditional If you 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 doesn t crossload changes
93. g disqualification 5 375 7d 57 The partner AM screamed 743404 11 30 2004 15 23 2 1756 VE 69 Equally Able To Control 743403 11 30 2004 15 23 02 373 5 1757 SRM 14 Chassis Redundancy State ck 743402 1173022N0N4 15 23 02 3202 T7AR FWFR 44 Fntered Qualification Phase 4 Chassis A Event Log Time Slot Module Description 5517 11 30 2004 15 41 20 050 5 1757 SRM 1E Chassis Redundancy State ck 5516 11 30 2004 15 40 17 086 5 1757 SRM 4D WCT time change gt 1 secor 5515 11 30 2004 15 23 24 914 5 1757 SAM 1D Chassis Redundancy State ct 5514 11 30 2004 15 23 24 498 1 1756 CNB 1 Transition to Not Lonely Publication 1756 UM523F EN P September 2006 Event description Autoqualification Trigger Blank Memories Rule Maintain and Troubleshoot the System 117 Interpret SRM events Use this table to interpret events recorded in the SRM s event log 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 Chassis Modules Rule 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 modul
94. gure and Program the Controller Action 8 Group your data by how often you need it Details 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 DINTs that you use only as constants to initialize your logic You have some BOOLs that you update every scan And you have some REALs that you update every second This is better Tag Name Type One user defined data type for the E My Bools My_Bools UDT BOOLs The controller crossloads these My_Bools Bool_1 BOOL 4 bytes every scan My_Bools Bool_2 BOOL My Bools Bool_3 BOOL One user defined data type for the DINTs My Constants My_Constants_UDT The controller crossloads these 12 bytes My_Constants Constant_1 DINT only once My_Constants Constant_2 DINT My_Constants Cosntant_3 BINT One user defined data type for the REALs My Reals My_Reals_UDT The controller crossloads these 12 bytes _My_Reals Real_1 REAL every second My_Reals Real_2 REAL
95. he new primary chassis after a switchover Router Use this appendix to show you how Switch Switch Primary Secondary chassis chassis Same subnet Stop Use IP swapping instead This lets you use the same IP address regardless of Switch which chassis is primary See Chapter 2 Primary Secondary chassis chassis When primary and secondary chassis are on different EtherNet IP subnets they keep their IP addresse s during a switchover This means that your and other controllers must be able to switch between the IP address of each redundant chassis How to Use This Chapter This chapter provides the following information Topic Page Keep an HMI Communicating with the Primary Chassis 150 Keep a Message Going to the Primary Chassis 156 Publication 1756 UM523F EN P September 2006 150 Set Up EtherNet IP Communication Across Subnets Keep an HMI Communicating with the If you re 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 To 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 topi
96. hen 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 161 Determine Which Chassis is Primary If ChasA_RedundancyState 2 3 or 4 then ChasA_IsPrimary 1 Chassis A is the primary chassis Chas4_IsPrimary LIM lt lsPrimary 0 gt Limit Test CIRC Low Limit 2 Test Chas4_RedundancyState pe High Limit 4 If ChasB_RedundancyState 2 3 or 4 then ChasB_IsPrimary 1 Chassis B is the primary chassis ChasB_IsPrimary LIM lt lsPrimary 1 gt Limit Test CIRC Low Limit 2 Test ChasB_RedundancyState o High Limit 4 Tag Name Description Alias For Data Type ChasA_RedundancyState Redundancy state of the Chassis A DINT 2 PwOS 3 PwDS 4 PwNs ChasB_RedundancyState Redundancy state of the Chassis B DINT 2 PwOS 3 PwDS 4 PwNS Publication 1756 UM523F EN P September 2006 162 Set Up EtherNet IP Communication Across Subnets Tag Name Description Alias For Data Type 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 memor
97. iIB M M X bo Lt 1756 CNB B or 1756 CNBR B module Remote chassis Other modules 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 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 1756 CNB D E or 1756 CNBR D E modules Publication 1756 UM523F EN P September 2006 If You Have Series B ControlNet Bridge Modules 179 Restriction Description If the Lowest Node Is a 1756 CNB B If the lowest node on a ControlNet network is a 1756 CNB B or 1756 CNBR B module all or CNBR B Module Removing a Tap communications over the network could stop if or Breaking a Cable Could Stop All Communications over the Network e a tap to the 1756 CNB B or CNBR B module is disconnected or breaks and then is replaced while power is still applied to the 1756 CNB B or CNBR B module If a tap to a 1756 CNB B or CNBR B module becomes disconnected or broken take these actions 1 Turn
98. ia n n anaana aaea 35 Redundant Power Supplies o on anaana aaa 36 Check Connection Requirements 004 37 Plan the ControlNet Networks nan go Va eas aes ee Saws 37 Plan the EtherNet IP Networks gnc icy a 9 a gon fai grain Baca ans 40 Worksheet for IP Swapping 4 oe Set OR aed ed Eso a 41 How an EtherNet IP Module Handles a Cable Break 42 Additional Considerations 5 207 gins dead ay oe WS De Ges 43 Chapter 3 When to Use This Chapter fu shpat cae what we ie eo 45 Publication 1756 UM523F EN P September 2006 6 Table of Contents Configure the System Redundancy Module Publication 1756 UM523F EN P September 2006 How to Use This Chapter ices 4c t1 4 a2u bon a ina ane aentbrgen Sou 45 Preliminary Information 4 id REESE wk Bed eee eee me BS 45 Install the Chassis for the Controllers 4 47 Install Modules in the First Redundant Chassis 48 Install Modules in the Second Redundant Chassis 50 Install the Remote Chassis or Rails 0005 51 Configure the EtherNet IP Modules gave ga Gy exae Bee Ba Pe 52 Flash the Modules 2 4 i0 4459 0 oar a4 aroha bem am erable aes 53 Check Your Installation 40 052 402 0 dd ets Bate dua Gal sues 53 PUD OSES raea E Ae N ee N E ka a els 53 Wenta gutaa oara an ota a E bones OEA e bate 53 PONS k eup aeo cae hoe Ee Sn a E ee OB eh a 54 Chapter 4 Purpose OF this Chapter n anaa aaa 55 When to Use this Chapter n a
99. ic that is scan dependent 8 Produced and If you want a controller in another chassis to consume a tag from the redundant controller use 74 consumed tags a comm format of None In the 1 0 configuration of the consuming controller select a comm format of None for the remote CNB module the CNB that is physically in the redundant chassis 9 Message MSG For any MSG instruction from a controller in another chassis to a redundant controller cache 74 instructions the connection Publication 1756 UM523F EN P September 2006 Operator Interface Terminals ControlLogix Redundancy Overview 25 Parameter For any of these operator interfaces Criteria Page 1 EtherNet IP network PanelView Standard terminal Same as a nonredundant system 30 34 40 e PanelView Plus terminal e Use RSLinx Enterprise software revision e VersaView industrial computer running a 3 0 or later Windows CE operating system e 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 e Use RSLinx Enterprise software revision RSLinx Enterprise software 3 0 or later e Use IP swapping e Keep the HMI and both redundant chassis on the same subnet e RSView Supervisory Edition software with Limit the number of RSLinx servers that a RSLinx 2 x software controller uses to 1 ideal to 3 maximum e
100. idge Through a Series B ControlNet Bridge Module Appendix D If You Have Series B ControlNet Bridge Modules This appendix describes several situations that could happen if you use series B of a ControlNet Bridge module Topic Page Communication Loss If You Bridge Through a Series B ControlNet Bridge Module 175 Communication Could Stop If You Use a Series B ControlNet Bridge Module 177 Situation You could 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 e 1756 DHRIO module that is connected to a remote I O network Publication 1756 UM523F EN P September 2006 176 If You Have Series B ControlNet Bridge Modules Redundant chassis pair ae x Fon i Waa 1756 CNB B or 1756 CNBR B module Remote chassis Remote 0 On the first switchover after you download a project to the controller you ma IMPORTANT eee proje vou may temporarily lose communications with these devices 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 faul
101. ies MSGs_5563 15 x Major Faults Minor Faults Date Time Advanced SFC Execution General Serial Port System Protocol User Protocol File Redundancy Nonvolatile Memory Memory IV Redundancy Enabled Redundancy Status Chassis Id 4 Chassis State Primary with Sp ized Secondary Module State Primary with Synchronized S Module Compatibility Fully Compatible Partner For More Information For more information on Attributes of the REDUNDANCY object 4 Compare the Redundancy tab with your code In this example the chassis ID A 1 GSV Get System Value lass Name Insta Attribute Na Dest REDUNDANCY See Appendix C GSV and SSV instructions Condition Logic to Run After Purpose a Switchover Logix5000 Controllers General Instructions Reference Manual publication 1756 RM003 To condition a section of your logic to run after a switchover Publication 1756 UM523F EN P September 2006 Configure and Program the Controller When Follow these examples to create logic in preparation for a possible switchover Example 1 Ladder Diagram Get the ID of the primary chassis That s always the chassis that runs the code Store the ID in the Chassis_ D_Now tag Chassis_ID_Now DINT GSV Get System Value Class Name REDUNDANCY Instance Name Attribute Name PhysicalChassisID Dest Chassis_ID_Now 1 If this is the first scan then Set the last val
102. ification 5302 11 30 2004 09 36 27 929 2 1756 EWEB 69 Equally Able To Control State Changes 5301 11 30 2004 09 36 27 901 5 1757 SRM _ 14 Chassis Redundancy State changed ad State Changes Publication 1756 UM523F EN P September 2006 Actions Maintain and Troubleshoot the System 115 Details 3 Look through the events of the secondary A Start with the secondary chassis chassis for a substantial change in log times Here s a substantial change in the log time The slot module and description columns show that the 1756 EWEB module in slot 2 went lonely That usually means it lost its network connection e The lower list is the secondary chassis e The 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 The SRM logs only significant events It doesn t 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 117 to interpret the description Example Auto Update Partner Log ON OFF OPEN CLOSE Export Selec Chassis B Event Log Time Slot Module Description Classification 743355 11 30 2004 14 27 18 208 2 1756 EWEB 69 Equally Able To Control State Change 743354 11 30 2004 14 27 18 196 5 17
103. igure 74 controller configure 72 connection 37 download project 98 install 48 nonvolatile memory 137 periodic task 126 program scan time 77 79 project 69 requirements 22 31 synchronize 53 122 system overhead time slice 124 watchdog time 102 ControlLogix5555 controller 22 ControlLogix5561 controller 22 ControlLogix5562 controller 22 ControlLogix5563 controller 22 ControlNet network assign addresses 37 general lay out 30 guidelines 37 keeper signature 100 110 redundant media 35 schedule 98 conversion to redundant system 165 corrected anomalies redundancy revision 15 56 27 crossload 16 18 estimate time for 77 D data crossload 18 integrity 85 DeviceNet network design 21 33 disqualified overview 16 troubleshoot 106 download 98 E edit edit online 18 69 Publication 1756 UM523F EN P September 2006 186 Index edit session in progress troubleshoot 111 ENBT module addresses during a switchover 20 configure 52 requirements 23 enhancements redundancy revision 15 56 26 estimate program scan time 77 EtherNet IP network alias topics 149 configure modules 52 design 21 33 40 guidelines 40 IP swapping 20 module requirements 23 proper use 181 without IP swapping 149 event log export 119 interpret 113 event task 20 EWEB module addresses during a switchover 20 configure 52 requirements 23 export event log 119 F FFU instruction 85 finalize online edits 71 firmware update
104. ime and reconnect the ControlNet tap Maintain and Troubleshoot the System 135 Action Details 8 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 don t have to browse the entire network C Select Network gt Keeper Status ControlNet_1 xc RSNetWorx for ControlNet Eile Edit View Network Device Diagnostics Tools Help 4 i Single Pass Browse Continuous Browse I Edits Eni s Online F10 Current Network Up Enable Edits cheduled Band 31 66 Unschedule cheduled Band Network Usag 34 71 Upload from Network Download to Network Hardware Download Minimum to Network ControlNe GA G Sais an D Select the node number of the secondary CNB and click Update Keeper 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 Valid Keeper Offline File Oxd2978909 a Oxd2978909 02 0xd2978909 k Unconfigured 05 NO YES Oxd2978909 06 NO YES Oxd2978909 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 synch
105. in the 1 All CNB modules in each redundant chassis are series D modules primary and secondary chassis don t match in 2 Each CNB module has a partner in the same slot in the other some way redundant chassis 3 Each pair of CNB modules one in each chassis is set to the same node address 4 Each module has compatible firmware 5 All CNB modules in each redundant chassis are valid keepers See Update a Keeper Signature on page 110 CMPT Some module other than 1 Each module has a partner in the same slot in the other redundant this CNB module doesn t chassis match between the primary and secondary chassis 2 Each pair of controllers one in each chassis has the same memory board for example 1756 L55M14 3 Each module has compatible firmware 4 The RSLogix 5000 project is configured for the right type of controller and redundancy is enabled See Configure a Controller for Redundancy on page 72 5 The Module Configuration window for the 1757 SRM module does not list any reasons for the failure to synchronize See See if an Edit Session Is in Progress on page 111 DUPLNODE More than one device on 1 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 number For example if the CNB modules are set to 3 no other device should be set to 4 2 The 1757 SRCx cable is connected to both SRM modules NET ERR The ControlNet media is All Con
106. ion 11 or earlier e your system isn t operating yet During this procedure you won t 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 ll 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 Maintain and Troubleshoot the System 143 Action Details 1 Update the software A Go to the tool tray of your computer and shutdown RSLinx software Restore Bale E 11 02 AM B Update the following software 1 1757 SRM System Redundancy Module Configuration tool 2 RSLogix 5000 software 3 RSLinx software 4 RSNetWorx software 5 ControlFLASH firmware update kit If you re planning to uninstall version 13 of your RSLogix 5000 software wait until you ve completed and validated your update 2 Add the latest EDS files Start Programs Rockwell Software RSLinx Tools EDS Hardware Installation Tool 3 Put the keyswitches in the REM position Put the keyswitch of each redundant controller to the REM position Otherwise you won t be able to update the system 4 Open the SRM configuration tool forthe A Start RSLinx software primary cha
107. 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 e create a DDE OPC topic for each controller e create an alias topic e set up the alias topic switcher e 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 between your HMI project and the primary controller after a switchover To install the Alias Topic Switcher software use the Contro lLogix 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 ControlLogix Redundancy Alias Topic Switcher SoU Sh SEO Sa yy Publication 1756 UM523F EN P September 2006 152 Set Up EtherNet IP Communication Across Subnets Configure a Driver to Communicate with the Primary and Secondary EtherNet IP Modules 1 Start RSLinx software File Edit View Communications Station DDE OPC Security Window Help 5 S18 lR x Available Driver Types a 2 Click 5 Ethernet devices 3 Select Ethernet devices and choose _AdiNew Choose a name f
108. les for the CNB modules if you haven t 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 thru 4 for the rest of the CNB modules 6 Go to Actions and start the procedure Don t have a nonredundant Go to Actions and start the procedure You ll have to use the secondary chassis with an open slot chassis to update the modules Publication 1756 UM523F EN P September 2006 132 Maintain and Troubleshoot the System l Actions Action Details 1 Add the latest EDS files Add the revision 11 EDS files for the 1756 CNB and 1756 CNBR modules if you haven t i 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 E Module Properties Local 4 1756 CNBR D 5 1 General Connection RSNetWor Module Info Backplane Type 1756 CNBR D 1756 ControlNet Bridge Redundant Media Vendor Allen Bradley Name Loca CNB Node P Description Slot a Revision 5 viel Electronic Keying Compatible Keying hed C Save the project 3 Open the SRM configuration tool for the A Start RSLinx software primary chassis
109. ll the way to Jags You are able to change this setting only 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 CNB Usage For each CNB module in a redundant chassis keep CPU usage to less than 75 percent e Each redundant CNB module needs enough additional processing time for redundancy operations e At peak operations such as synchronization redundancy uses an additional 8 percent approximately of the CPU of the CNB module e A total CPU usage that is higher than 75 percent may prevent a secondary chassis from synchronizing after a switchover To reduce the CPU usage of a module take any of the following actions e Change the network update time NUT of the ControlNet network Typically increase the NUT to reduce the CPU usage of a CNB module e Increase the requested packet interval RPI of your connections e Reduce the number of connections to through the CNB e Reduce the number of MSG instructions e Add another CNB module to each redundant chassis Publication 1756 UM523F EN P September 2006 128 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 ch
110. lly Able To Control State Changes 743583 12 2 2004 16 02 27 050 5 1757 SRM 14 Chassis Redundancy State changed State Changes FAIRA 12722 2NNA 16 NP 9 GRF 17RR F WFR 441 Pritered Mitalificatinn Phase A Ctate Channec Export Event Log 3 x File name Browse File Type Text CSV Comma Separated Value B Click the Browse button and choose a location and name for the export file C Choose CSV Comma Separated Value D Select the nclude Extended Information check box I Include Extended Information E Choose Export Cancel Publication 1756 UM523F EN P September 2006 122 Maintain and Troubleshoot the System Manually Synchronize the After a switchover you may have to manually synchronize the chassis ecause either Chassis i g e the Auto Synchronization option is not set to Always or e the chassis failed to synchronize To manually synchronize the chassis 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 E Workstation FF Linx Gateways Ethernet AB_KTC x ControlNet F n 1756 CNB D E F Backplane 1756 Ax pe xX 1756 module 1757 SRM 4 Right click the 1757 SRM module and select Module Configuration 5 Click Synchronization 1757 SRM REDUNDANCY MODULE a Module Info Configuration
111. ly crossloads the project to the secondary controller IMPORTANT If the secondary chassis becomes disqualified after you download the project make sure that you e configured the project for the right type of controller e enabled redundancy See Plan for Online Edits on page 69 1 Open or create the RSLogix 5000 project for the controller 2 From the File menu choose Save 3 From the Communications menu choose Who Active 4 Browse to the controller in the primary chassis A Open a branch in one of these ways F 1 Workstation e Double click it m Linx Gateways Ethernet peer k e Click its sign ESE 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 x 1756 controller 5 Select the controller and choose Download A confirmation box opens 6 Choose Download Schedule the ControlNet Networks IMPORTANT Before you schedule a ControlNet network turn on the power to both redundant chassis If you schedule a ControlNet network while the secondary chassis is off the keeper signature of a CNB module may not match its partner and the secondary chassis will fail to synchronize Publication 1756 UM523F EN P September 2006 Configure and Program the Controller 99 To schedule a ControlNet network e schedule a new
112. m the Controller Notes Publication 1756 UM523F EN P September 2006 Chapter 6 Maintain and Troubleshoot the System When to Use This Chapter This chapter provides a variety of procedures to commission upgrade Simultaneous power of redundant chassis pair may bump another redundant chassis pair off the EtherNet IP network How to Use This Chapter If you want to maintain and troubleshoot your redundancy system Under the following combination of conditions all must apply duplicate IP addresses on your EtherNet IP network will cause you to lose communication with a redundant chassis pair over that 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 Then see this section Page e Find the cause of an unplanned switchover Find the Cause of a
113. mary Chassis 15 What Causes a Switch from One Controller to Another 15 Can I Use a Network Access Port 2 20 00 000000 16 Do I See a Bump in Outputs During a Switchover 16 How Does the Second Controller Stay Up to Date 16 What If I Make Online Edits o4 4 p43 va ei oad Pace ees RRS 18 Does My Scan Time Increase nnua ak ed pee en eae 18 What Happens to Network Addresses During a Switchover 18 If You Have a ControlNet Network 19 If You Have an EtherNet IP Network 20 What Can t I Do with a Redundant System 20 Quick Start Checklists es s c a eG RG Se OA os 21 System Layout sas Ea a vi eee Sree AEE GE Asie 21 Redundant Chassis Configuration 22 RSLogix 5000 Project ooa en ta cuah eos aaah e Ka ead ede s 23 Operator Interface Terminals n aana aaau 25 Compatible Software Versions nnana aaa 26 Enhancements to Redundancy Revision 15 56 26 Corrected Anomalies in Redundancy Revision 15 56 27 Chapter 2 How to Use This Chapter nnana aaa aaa 29 Lay Out the System 2 2 ee 30 Place the Pair of Redundant Chassis 32 If You Need More Than 100 Meters Between Chassis 32 Placethe TO fa oes pase ga ete Be GT Kong E ORG pe BAG ont e owe 8 33 Place Operator Interface Terminals nananana aaa 34 Add Additional Redundant Components 35 Redundant ControlNet Med
114. me Enmary Interpret the SRM Event Log Purpose To look through a log of events to see why the system switched over or failed to synchronize When Perform this procedure when e a switchover happens but your system synchronizes again e you ve already tried to use the hardware lights to find why your system won t synchronize 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 Publication 1756 UM523F EN P September 2006 114 Maintain and Troubleshoot the System Actions Actions Details 1 Open the SRM configuration tool for the A Start RSLinx software primary chassis bated 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 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log Identification Status Vendor Rockwell Automation Goer ag Allen Bradley Major Fault Nor Product Type Redundancy Product 2 Go to the event log Click Event Log 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log Auto Update Partner Log fe i i C OFF OPEN CLOSE Chassis A Event Log Time Slot Module Description Class
115. na ne oo danke eens ie AGae cs 131 ACHONS airi od tue A Ramee Pees PRS de eos 132 Store or Load a Project Using Nonvolatile Memory 137 Store a Project to Nonvolatile Memory While a Process Is Running 304 405 dads tog ot achat ak tle Gea ee PA 139 Wpcate A Modalen ors ia IN Aes a ee eae 140 Update a System That Is Already at Revision 13 142 Appendix A Purpose OF This Chapter 26s on wy ete eee at oe 149 When to Use This Chapter stone 4 nes eta eae Rote 149 How to Use This Chapter lt 2 0 4 fo Srexe ecu oxween 149 Keep an HMI Communicating with the Primary Chassis 150 Install the ControlLogix Redundancy Alias Topic Switcher SOM W AES hn OAS E atin ian aa ein Bee Rae eee oe 151 Configure a Driver to Communicate with the Primary and Secondary EtherNet IP Modules i544 2464 ae Pw RS 152 Create a DDE OPC Topic for Each Controller 153 Create an Alias TOpiC 54 64 ond Fo8 b oe Boers Ss baeaes 154 Set Up the Alias Topic Switcher 155 Address the Alias Topic in the HMI Project 156 Keep a Message Going to the Primary Chassis 156 Create a Periodic Trigger for the Messages 157 Get the Redundancy State of Chassis A 158 Get the Redundancy State of Chassis B 159 Determine Which Chassis is Primary 161 Send the Message to the Appropriate Controller 162 Appendix B Introduction hoe asi act fhe Me eon bom datuct ot teen ot prona
116. nchronization Status Event Log Auto U pate Partner Log OPEN C CLOSE Export Selection E ent _ Log Tne Slot Module Description Classification 743584 2004 16 02 27 055 2 1756 EWEB 69 Equally Able To Control State Changes 743583 12 2 2004 16 02 27 050 5 1757 SRM 14 Chassis Redundancy State changed State Changes 743582 12 4 2004 16 02 26 967 2 1756 EWEB 44 Entered Qualification Phase 4 State Changes 743581 7 2 2004 16 02 26 917 5 1757 SRM 2E Qualification Complete Qualification 743580 2 2004 16 02 26 891 2 1756 EWEB 46 Entered Qualification Phase 3 State Changes 743579 2 2004 16 02 25 892 2 1756 EWEB 3E Entered Qualification Phase 2 State Changes 743578 4 2 2004 16 02 24 405 2 1756 EWEB 39 Entered Qualification Phase 1 State Changes FAan p 2720N4 1A N2 24 382 5 1757 SRM 2D Qualification Attennted Qualification Chassis Event j og Time Slot Module Description Classification E 4 14 5 C P nmunIC 5716 12 2 2004 15 38 1 1756 CNB f Transition to Not Lonely 4 Export your selection A Choose Export Selection 1757 SRM REDUNDANCY MODULE oj x Module Info Configuration Synchronization Synchronization Status Event Log Auto Update gt p Partner Log ON C OFF OPEN C CLOSE Export Selection Chassis B Event Log Time Module Description Classification 743584 12 2 2004 16 02 27 055 2 1756 EWEB 69 Equa
117. nchronizing synchronized qualified secondary qualifying secondary secondary Actions Details A Start RSLinx software 1 Open the SRM configuration tool for the 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 1757 SRM REDUNDANCY MODULE r Module Info Configuration Synchronization Synchronization Status Event Log Identification Status Vendor Rockwell Automation General State OK Allen Bradley Major Fault No Product Type Redundancy Product Publication 1756 UM523F EN P September 2006 64 Configure the System Redundancy Module Action Details 2 Start a switchover A Click Synchronization 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log Disqualify Secondary Initiate Switchover Become Biman Commands B Choose nitiate Switchover and then choose Yes to continue 3 Monitor the synchronization progress A Click Synchronization Status 1757 SRM REDUNDANCY MODULE Synch Resssceensesseseee Module Info Configuration Synchronization Slot Complete Module Secondary Readiness State Compatibility o 1756 L55 Synchronizing Primary Full lt empty gt s z lt empty gt lt empty gt 19 1756 CNBR Synchronizin
118. ndary controller A The following data is sent to the secondary controller e Data from the program in the higher priority task e Data from the first part of the program in the lower priority task B Execution returns to the program in the lower priority task C The secondary controller e starts the scan at the beginning of the program that was in progress in the primary controller 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 September 2006 Configure and Program the Controller 87 Look for Array Shift Instructions The following instructions might corrupt data during a switchover e BSL e BSR e FFU Because these instructions shift data within an array an interruption by a higher priority task and a subsequent switchover leaves the data with an incomplete shift e If a higher priority task interrupts one of these instructions the partially 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 executi
119. nded Information Definition Chassis A x Event Information Event Number 5347 Log Time 11 30 2004 etal EJ Event Class Starts Stops m Submitter Information Module Type 1757 5RM Slot No 5 Serial No in Hex 204F29 Event Details Description 2B Module Removal Extended Data Definition Module hemeved From cha Removed module a iG See value in byte 1 of Extended Information Byte Someone removed the module for slot 2 Or the module failed Extended Information Bytes in Hex 5 If the secondary log doesn t show the Sometimes you have to use both logs to find out what happened cause look at the primary log Example A The secondary log shows that something happened around 15 40 But it s not clear just what happened Module Info Configuration Synchronization Synchronization Status Event Log m Auto Update Partner Log B The primary log shows that around that ON OFF OPEN C CLOSE time the partner SRM screamed That Chassis B means it lost power Event Slot Module Description Log Time 743409 11 30 2004 15 39 54 4068 5 1757 SRM 55 The partner RM has been con 743408 11 30 2004 15 39 09 447 2 1756 EWEB 4D Replied to disqualify commanc 743407 11 30 2004 15 39 09 417 5 1757 SRM 18 Chassis Redundancy State ch 743406 11 30 2004 15 39 09 37 2 1756 Audy 30 Processin
120. ne the Status of Purpose Your Redundancy System To write code that determines the status of your redundancy system When 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_ D_Now tag Chassis_ID_Nowis a DINT GSV Get System Value Class Name REDUNDANCY Instance Name Attribute Name PhysicalChassisID Dest Chass s_ID_N ow 1 Example 2 Structured Text comment Get the ID of the primary chassis comment comment That s always the chassis that runs the code Store the ID in Chassis_ID_Now Chassis_ID_Now is a DINT code GSV REDUNDANCY PhysicalChassisID Chassis ID Now Publication 1756 UM523F EN P September 2006 Configure and Program the Controller 91 Check Your Work Use the Redundancy tab of the Controller Properties window to check the code attributes It doesn t 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 fo Controller Propert
121. new logic onfigure how to reserve unused memory between tags and You do this online in program mode Then Notes Leave the default setting While online create a relatively large amount of new tags but a much smaller amount of new logic Drag to slider toward Jags Avoid setting the slider all the way to Tags 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 logic but a much smaller amount of new tags Configure a Controller for 1 Redundancy Publication 1756 UM523F EN P September 2006 Drag to slider toward Logic Avoid setting the slider all the way to Logic you will be unable to create tags while online Open or create the RSLogix 5000 project Offline J M RUN E No Forces 2 M Ok No Edits a a 1 0 Redundancy W9 j 2 On the Online toolbar click the controller button Does General display the controller type e If no go to step 4 e If yes go to step 7 Click the Change Type button Select your controller Choose OK Click Redundancy Configure and Program the Controller 73 8 Select the Redundancy Enabled check box oe e 9 Click the Advanced button Advanced Redundancy Configuration 10 We recommend that you not check this box Leaving it unchecked prevents an incorrect online edit from faulting both the primary and secondary controller If you wan
122. o 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 Ua Wai Labels may be located on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present PTD avai Labels may be located on or inside the equipment for example a drive or motor to alert people that surfaces may be dangerous temperatures gt pP Pree Allen Bradley RSLogix RSLogix 5000 RSNetworx DH PanelView PanelViewPlus and VersaView are trademarks of Rockwell Automation Inc RSView and RSLinx are registered trademarks of Rockwell Automation Inc
123. odule Redundancy Module 42801 Publication 1756 UM523F EN P September 2006 Actions Turn on the chassis power to the partner secondary chassis Wait for the 1757 SRM module to complete its power up cycle e The SRM module takes 1 to 3 minutes to power up e It may also take several minutes to synchronize the secondary controller Does 1 of the 1757 SRM modules show PRIM and the other module show SYNC e Yes Stop The system is synchronized e No There is a problem The system isn t synchronized Go to step 4 Make sure that the Auto Synchronization option of the SRMs is set to Always For help see Chapter 4 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 5 Purpose of This Chapter When to Use This Chapter Chapter 4 Configure the System Redundancy Module This chapter shows how to set or change the configuration of a 1757 SRM module The SRM 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 How to Use This Chapter Use this chapter as follows If Do this On page You just installed your system Open the SRM Configuration Tool
124. 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 ControlNet network 1 Go online to the controller 2 Save the project Publication 1756 UM523F EN P September 2006 102 Configure and Program the Controller Set the Task Watchdog Give a redundant controller longer watchdog times than a nonredundant controller Times 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 the following formula to set the minimum watchdog time for a task task Minimum watchdog time 2 maximum_scan_time 150ms 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 FF Controller Primary EF Tasks F MainTask A Right click the task and choose Properties B Click Configuration ig Task Properties MainTask 1O x General Configuration Program Schedule Monitor Type Continuous
125. olNet Bridge Redundant Media Vendor Allen Bradley Name Local_CNB Node Description Slot Revision 1 7jeji E all ectronic Keying Compatible Keying x controller Term Description Nonvolatile memory controller is without power or a battery Memory of the controller that retains its contents while the 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 Publication 1756 UM523F EN P September 2006 138 Maintain and Troubleshoot the System In a redundant system store or load a project only while the secondary chassis is disqualified 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 Se gt on o N oe co 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 Disqualify the secondary chassis Store the project that is in the primary controller For step by step procedures on ho
126. oller Synchronization occurs when power is applied to the secondary chassis and after a switchover is diagnosed and fixed Synchronized The secondary chassis is ready to assume control if the primary chassis fails Disqualified The secondary chassis isn t synchronized with the primary chassis If a secondary chassis is disqualified it can t take over control of the machine or process A secondary chassis can be manually disqualified Qualify Same as synchronize Qualified Same as synchronized The 1757 SRM modules keep communication between the primary and secondary chassis Primary chassis e Don t 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 Crossload 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 1757 SRM modules online edits force values changes to properties changes to data 43129 Secondary chassis results of logic execution Publication 1756 UM523F EN P September 2006 18 ControlLogix Redundancy Overview What If Make Online Edits Does My Scan Time Online edits automatically crossload to the secondary cont
127. on a CompactFlash card See page 137 e motion control such as the following modules 1756 HYD02 Publication 1756 UM523F EN P September 2006 Quick Start Checklists ControlLogix Redundancy Overview 21 1756 L60M03SE 1756 M02AE 1756 M02AS 1756 M03SE 1756 M08SE 1756 M16SE The following checklists provide a summary of the criteria for a successful ControlLogix redundancy system See the remaining chapters for more information on each parameter No EtherNet IP network for e control of 1 0 System Layout Parameter Criteria Page 1 ControlNet networks e ControlNet networks are the primary networks for the system 30 33 e OK to bridge to devices on other networks such as DeviceNet Universal Remote 0 and DH networks e Networks follow the guidelines in Logix5000 Controllers Design Considerations publication 1756 RM094 2 1 0 Placement e All I O modules in remote chassis or DIN rails no 1 0 in the local chassis 30 33 e All 1 0 in ONLY the following locations e same ControlNet network as the redundant controllers no bridging e DeviceNet network via a 1756 DNB module in a remote chassis e universal remote I O network via a 1756 DHRIO module in a remote chassis 3 ControlNet network update e NUTs 90 ms 37 times e NUTs lt Specified relationship to each other 4 Number of ControlNet nodes At least 2 nodes on each network in addition to the CNBs in the redundant chassis Fo
128. on 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 For example scan_count CU CTU Count Up Counter scan_count Preset Equal EAE Source scan_count ACC 0e Source B 1000 43065 A The CTU instruction counts each scan B The EQU instruction uses the count of each scan scan_count ACC Publication 1756 UM523F EN P September 2006 88 Configure and Program the Controller C If a higher priority task interrupts the logic the value of scan_count ACC is sent to the secondary controller at the end of the program in the higher priority task D If a switchover occurs before the EQU instruction the secondary controller starts its execution at the beginning of the program The EQU instruction misses the last value of scan_count ACC Take Preventative Actions If logic seems susceptible to an upset during a switchover take one of the following preventative actions 1 Place susceptible logic in the highest priority task 2 If the logic must remain in a lower priority task take one of the following actions e Use UID and UIE Instruction Pairs e Buffer critical data Place Susceptible Logic in the Highest Priority Task e This prevents the controller from sending any data to the secondar
129. ondary controller As the primary controller executes its logic it updates the secondary controller at the end of every program Interruption by the program End of the program in a in a higher priority task higher priority task Start of the program in the lower priority End of the program in the lower task for example the continuous task priority task A Primary controller AV A The following data is sent to the secondary controller e Data from the program in the higher priority task e Data from the first part of the program in the lower priority task B Execution returns to the program in the lower priority task C Data from the second part of the program in the lower priority task is sent to the secondary controller When a switchover interrupts the execution of the primary controller the secondary controller reexecutes an interrupted program from the beginning of the program Publication 1756 UM523F EN P September 2006 86 Configure and Program the Controller Interruption by the program End of the program in a in a higher priority task higher priority task Start of the program in the lower priority task for example the continuous task Primary controller A e This portion of the task is not executed during this scan e Instructions executing at the time of the a g switchover do not complete in this scan Switchover J occurs Seco
130. onfiguration tool only with revision 13 or later ControlLogix redundancy systems e RSLinx software version 2 43 or later automatically installs version 2 6 or later of the configuration tool e To connect to a revision 11 or earlier redundancy system uninstall the configuration tool and install a compatible version Use version 2 5 of the configuration tool for revision 11 redundancy systems Make sure your ENBT modules are catalog revision E01 or later Publication 1756 UM523F EN P September 2006 To use a 1756 ENBT module in a redundant controller chassis make sure its catalog revision is E01 or later Otherwise the secondary chassis won t synchronize with the primary chassis Allen Bradley Ethernet IP 10 100 To find the catalog revision of a module ControlLogix look at the label on the side of the 1756 ENBT EOI module or box L Catalog revision Example Use a catalog revision such as E01 E02 or F01 Redundant System Restrictions 183 Restriction Details For a series B controller with 1 7 firmware Example use a nonredundant chassis to update it the first time You just took the controller out of its box Its label shows that it is a series B controller with 1 7 firmware as in the following example LOGIX 5563 PROCESSOR UNIT CATALOG REV PART NO Allen Braa CATALOG SERIGS 1756 L63 B In this case 1 Put the controller in a nonredundant chassis 2 Update the controller 3
131. oose Module Statistics 4 Click Connection Manager Number of connections used CPU usage 42903 Look at the Four Character Display at Nog The four character display on the front of the 1756 CNB D E or 1756 CNBR D E module shows the following information Publication 1756 UM523F EN P September 2006 Maintain and Troubleshoot the System 129 For this information about a Display Where CNB module Address of the module A xx xx is the node address of the module Percent of CPU usage Cxx xx is the percent of CPU usage The range for the display is 00 99 Number of open connections nCxx xx isthe number of open connections that the module is using Number of unconnected client Ucxx xx isthe number of unconnected client buffers that the module is using You see this buffers 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 Number of unconnected server Usxx xx Is the number of unconnected server buffers that the module is using You see this buffers 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 State of the module s keeper Kpxx xx is the state of the module s keeper function funeugn lf xx is Then the module is Ai Active network keeper with either e invalid ke
132. operties x Module Info Configuration Synchronization Status Event Log Commands Synchrontee Secondary Disqualitt Secondary Initiate Switchover Become Primary F Choose Become Primary Publication 1756 UM523F EN P September 2006 142 Maintain and Troubleshoot the System Action 6 Clear the fault of the new primary controller 7 Upgrade the other redundant chassis Details A In RSLogix 5000 software go online to the new primary controller B The controller is faulted When a disqualified secondary controller becomes a primary controller the controller experiences a major fault C From the Communications menu choose Clear Faults j To start control of the process from the Communications menu choose Run Mode A Turn on power to the other redundant chassis B Upgrade the required firmware of the chassis 8 Change the Auto Synchronization Option to ALWAYS Update a System That Is Already at Revision 13 Publication 1756 UM523F EN P September 2006 A Open the SRM configuration tool for the primary chassis ow C Choose OK On the Configuration tab change the Auto Synchronization option to Always Complete the following 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 revis
133. or the new driver 15 characters maximum JAB_ETH 1 Station Mapping Station Host Name Add New 4 Accept the default name amp o 10 88 89 55 1 Deco 5 Type the IP address of each ENBT or EWEB module 63 Diver To add another IP address choose 6 Choose and then 7 Click H Workstation 4B 1FF6CB4632FE Linx Gateways Ethernet Driver that you just added Modules in the redundant chassis 10 88 89 56 1756 ENBT A 10 88 89 55 1756 ENBT A 1756 ENBT A 10 88 89 56 1756 ENBT A 1756 ENBT A Publication 1756 UM523F EN P September 2006 Set Up EtherNet IP Communication Across Subnets 153 Create a DDE OPC Topic for Each Controller 1 Browse to the controller in Chassis A 2 Right click the controller and choose Configure New DDE OPC Topic 3 Rename the topic to indicate that this is Chassis A 4 Choose and then Yes update topic 5 Create a topic for the controller in Chassis B Workstation 4B 1FF6CB4632FE e Linx Gateways Ethernet Za AB_ETH 1 Ethernet 10 88 89 55 1756 ENBT A4 1756 ENBT A 10 88 89 56 1756 ENBT A4 1756 ENBT A Backplane 1756 A7 4 02 1756 L55 4 LO 5 1756 L55 4 03 1756 CNB D 1756 CNB D DOS 36 04 1756 ENBT A cr Channel 0 DF1 F DDE OPC Topic Configuration Project Default
134. ords e You must configure the controller for redundancy e You don t 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 MaxDataTransfer DINT This attribute gives the biggest size of the LastDataTransfer crossload Size Size attribute e Size of the biggest fe crossload if you had a e The size in DINTs 4 byte words secondary chassis e You must configure the controller for redundancy e You don t need a secondary chassis e Toreset 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 RM003 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 DINT s 1 ms overhead e f ControlLogix5561 then crossload time 0 0013 ms DINT s 1 ms overhead e f ControlLogix5562 then crossload time 0 0013 ms DINT s 1 ms overhead e f ControlLogix5563 then crossload time 0 0013 ms DINT s 1 ms overhead where DINT s is the size of
135. ot 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 fj Tag Properties MyProducedTag q General Connection Maximum Consumers r Both configurations always trigger an gt A J Programmatically IOT Instruction Send Event Trigger to Consumers event task during a switchover fi Tag Properties MyProducedTag J General Connection l Maximum Consumers fi V Programmatically IOT Instruction Send Event Trigger to Consumers Simultaneous Branch Delays the Execution of a Higher Priority Task Tran_000 MyCondition 1 In an SFC each path of a simultaneous branch delays the execution of a higher priority task by up to 25 us Pe Step_001 J Step_002 0 Publication 1756 UM523F EN P September 2006 44 Design the System Notes Publication 1756 UM523F EN P September 2006 Chapter 3 Install the System When to Use This Chapter Use this chapter to install the hardware of a ControlLogix redundancy system How to Use This Chapter To install the system complete the following tasks Topic Page Review the Preliminary Information 45 Install the Chassis for the Controllers 47 Install Modules in the First Redundant Chassis 48 Install Modules in the Second Redundant Chassis 50 Install the Remote Chassis or Rails 51 Configure the EtherNet IP Modules 52 Fl
136. ou 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 1 0 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 September 2006 38 Design the System Guideline 3 Set aside 2 consecutive ControlNet addresses for each pair of redundant chassis for example nodes 3 and 4 redundant chassis 1st pair of CNB modules Pair of CNB modules one in each 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 Slot and node numbers Slot Primary node Secondary node primary node 1 2nd pair of CNB modules 3rd pair of CNB modules Ath pair of CNB modules 5th pair of CNB modules 4 Know that the switchover time depends on the NUT of the
137. packs and a MySupport feature that you can customize to make the best use of these tools For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect Support programs For more information contact your local distributor or Rockwell Automation representative or visit http support rockwellautomation com Installation Assistance If you experience a problem with a hardware module within the first 24 hours of installation please review the information that s contained in this manual You can also contact a special Customer Support number for initial help in getting your module up and running United States 1 440 646 3223 Monday Friday 8am 5pm EST Outside United Please contact your local Rockwell Automation representative for any States technical support issues New Product Satisfaction Return Rockwell tests all of our products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned United States Contact your distributor You must provide a Customer Support case number see phone number above to obtain one to your distributor in order to complete the return process Outside United Please contact your local Rockwell Automation representative for States return procedure www rockwellautomation com Corporate Headquarters Rockwell Automation 777 Eas
138. ppens during a switchover 18 69 get 90 171 troubleshoot system overhead time slice 124 switchover 106 T U task update event 20 system that is already at revision 13 142 inhibit 20 update firmware 53 140 number of 126 watchdog time 102 test Ww switchover 63 watchdong time 102 test edits workstation connect to a NAP 16 Publication 1756 UM523F EN P September 2006 How Are We Doing PANE 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 1756 CNB D 1756 CNBR D 1756 ENBT 1756 EWEB Pub No 1756 UM523F EN P Pub Date September 2006 Part No 953030 15 1756 L55 1756 L55M12 1756 L55M13 1756 L55M14 1756 L55M16 1756 L55M22 1756 L55M23 1 1 756 L55M24 1756 L61 1756 L62 1756 L63 757 SRM Please complete 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 fa illustration L feature is provided L example C guideline L other C explanation C definition Technical Accuracy 1 2 3 Can we be more accurate all provided
139. process is running 139 proper use EtherNet IP network 181 0 qualify See synchronize REDUNDANCY object 171 redundancy revision 15 56 corrected anomalies 27 enhancements 26 redundant system compatible software versions 26 firmware combinations 14 restrictions 181 remote I 0 network Index 187 design 21 33 requested packet interval 74 restrictions redundant system 181 revision 13 updating system 142 RIO network design 21 33 S scan time See program scan time task scan time schedule a ControlNet network 98 secondary chassis troubleshoot 106 SRM configuration tool find the revision 57 open 55 SRM module auto synchronization 65 configure 55 enable program control 66 export event log 119 install 48 interpret event log 113 program control 66 send message to 94 set the clock 61 94 synchronization status 63 synchronize controllers 122 status of my redundancy system 90 store project to nonvolatile memory 137 project to nonvolatile memory while process is running 139 switchover causes 15 data integrity 85 diagnose cause 106 run code after 91 test 63 trigger with MSG instruction 94 troubleshoot 106 what happens to network addresses 19 20 what happens to online edits 18 synchronize controllers 122 diagnose failure 106 overview 16 status 63 Publication 1756 UM523F EN P September 2006 188 Index synchronize controllers 53 finalize 71 system information what ha
140. r 37 example each ControlNet network has at least 4 nodes 5 ControlNet node e Nonredundant nodes use the lowest node numbers 18 37 assignments e CNB modules in the redundant chassis set close to the 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 6 Network Access Ports No devices connected to the network access ports of CNB modules in the redundant 30 chassis 7 EtherNet IP networks EtherNet IP networks are only for HMls workstations and messaging no control of 1 0 30 40 e peer interlocking produced and consumed tags Publication 1756 UM523F EN P September 2006 22 ControlLogix Redundancy Overview Redundant Chassis Configuration Parameter 1 Chassis size Criteria Same size chassis for each pair of redundant chassis 2 Chassis layout e Only the following modules in each redundant chassis NO other modules e controllers e ControlNet modules e EtherNet IP modules e System redundancy module needs 2 slots e Each chassis within a redundant pair looks the same e Identical modules same catalog number series revision and memory size e Same slot assignments 3 System redundancy modules 1757 SRM module e 1 in each redundant chassis e Needs 2 slots e Needs 1757 SRCx cable 1 3 10 50 and 100 meter lengths 4 Controllers ControlLogix5555 ControlLogix5561 ControlLogi
141. r in redundant Chassis B Publication 1756 UM523F EN P September 2006 164 Set Up EtherNet IP Communication Across Subnets Notes Publication 1756 UM523F EN P September 2006 Appendix B Convert an Existing System to Redundancy Introduction 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 1756 L55Mxx controller from the original chassis and place it in a redundant chassis e Change any event tasks to periodic tasks You can t use event tasks in a ControlLogix redundancy system Convert Local Modules to If you are converting an existing system to a redundant system Remote Modules Aad ties Then Contained only I O modules that Do not change the 1 0 configuration of the controller were not in the same chassis as the controller Contained local 1 0 modules Use the procedures in this section to convert the configuration of local modules to remote modules To convert a local module to a remote module e reconfigure the lo
142. r power to recover Lgx00061808 Lgx00060991 Sometimes a module faulted after a switchover Sometimes a module would fault after a broken or disconnected communication cable caused a switchover The module showed a fault code of 16 0022 Lgx00061990 The SRM pair lost the fiber optic connection under heavy HMI traffic The synchronized pair of 1757 SRM modules would sometimes lose their connection across the fiber optic link under heavy HMI traffic conditions This caused the secondary chassis to become disqualified either with the SRM modules showing no partner or the secondary module showing error EA91 You had to remove and reinsert the secondary SRM module under power to recover Lgx00062847 Lgx00062839 Lgx00062171 Publication 1756 UM523F EN P September 2006 28 ControlLogix Redundancy Overview Corrected Anomaly Description The primary SRM module rejected a The primary 1757 SRM module rejected a synchronization command when synchronization command e the auto qualification option was set to Never and e the synchronization command was given within 30 seconds after disqualification of the redundant chassis pair The SRM module continued to reject any synchronization command You had to change the auto qualification option to A ways to synchronize the chassis Lgx00062954 Lgx00058896 Lgx00037660 ENBT module wouldn t reply to a ping Sometimes you wouldn t get a reply when you pinged a 1756 ENBT module
143. rolLogix Power Supplies Installation Instructions publication 1756 5 78 ControlLogix controller ControlLogix Controller and Memory Board Installation Instructions publication 1756 IN101 1756 CNB D E or CNBR D E module ControlLogix ControlNet Bridge Installation Instructions publication 1756 IN571 1756 ENBT module ControlLogix EtherNet IP Bridge Module Installation Instructions publication 1756 INO19 1756 EWEB module EtherNet IP Web Server Module Installation Instructions publication 1756 IN588 1757 SRM module Publication 1756 UM523F EN P September 2006 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 the following 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 Repeated electrical arcing causes excessive wear to contacts on both a module and its mating connector Worn contacts may create electrical resistance that can affect module operation Install the System 47 Preventing
144. roller 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 9 Increase executed in the program This results in an increased program scan time for a synchronized redundancy system lt Program Scan Time gt Execute program in Crossload results to primary controller secondary controller Start of program End of program What Happens to Network Each CNB ENBT or EWEB module in a redundant chassis shares a air of network addresses with its partner in the other chassis Addresses During a p j Switchover Publication 1756 UM523F EN P September 2006 ControlLogix Redundancy Overview 19 If You Have a ControlNet Network Set each pair of CNB modules to the same node number Secondary Primary chassis chassis CNB modules swap node numbers CNB modules in the primary chassis use the node number to which they are set Switchover
145. ronization 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 Evep r Redundancy Commands e Yes Go to step 3 Synchronize Secondary Disquality Secondary Initiate Si e No An edit session didn t stop synchronization Return to Troubleshoot a r Recent Synchronization Attempts Failure to Synchronize or page 108 Result Abort dit Session In Progress N 1 Success N 2 Success N 3 Success 3 Look for the reason If Then Another computer is editing the project in the controller Stop the edit session The project contains test edits Untest the edits The Nonvolatile Memory Load Store dialog box of the controller is open Close the Nonvolatile Memory Load Store dialog box You tried to synchronize the chassis while downloading a project at the same time Publication 1756 UM523F EN P September 2006 Wait for the download to finish Maintain and Troubleshoot the System 113 Actions Details 4 Manually synchronize the chassis Choose Synchronize Secondary and then Yes continue with synchronization 15 x 1757 SRM REDUNDANC f MODULE Module Info Configyfation Synchronization Synchronization Status Event Log Redundancy Co Synchronize Secondary Disquality Secondary Initiate Switchover Beco
146. ronized on the network This dialog provides insights into the keeper mismatch messages that appear in the Messages view Keeper Capable Node Valid Keeper Offline File Oxd2978909 0 Oxd2978909 02 Oxd2978909 Oxd29 8309 05 NO YES Oxd2978909 06 NO YES Oxd2978909 F Repeat steps D and E for the other CNB modules in the secondary chassis G Click Close ial El Publication 1756 UM523F EN P September 2006 136 Maintain and Troubleshoot the System Action 9 Reset the secondary CNB modules 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 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Event Log System Update Slot Complete Module Secondary Readiness State Compatibility 0 lt empty gt 1 _ lt empty gt 2 0 1756 L63 Disqualified Primary 3 lt empty gt 4 0 1756 CNBR Disqualified Primar 5 0 1757 SRM Disqualified Primar 6 lt empty gt 7 lt empty gt _ 8 0 1756 CNBR Disqualified Primary g 0 1756 ENBT Disqualified Primary 10 lt empty gt 10 Synchronize the secondary chassis The chassis are synchronized A Click Synchronization 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Update
147. running a Windows CE operating system RSView Supervisory Edition software Important For RSView Supervisory Edition software install the RSLinx Enterprise HOTFIX The HOTFIX improves the EtherNet IP switchover time See Knowledgebase document R154640079 To access Rockwell Automation s Knowledgebase go to http support rockwellautomation com i i RSLinx Enterprise 3 0 You need this only for these HMIs B RSLogix 5000 15 01 p RSNetWorx 5 11 Enhancements to The following enhancements apply to a redundant system using revision 15 56 Redundancy Revision 15 56 Enhancement Update the firmware of the redundant chassis while the process is running Description This revision lets you update the firmware in the redundant chassis without shutting down the process To do this the system must be at revision 13 Add 0 modules while online Publication 1756 UM523F EN P September 2006 At runtime add 1756 I O modules to a remote chassis via the unscheduled portion of a ControlNet network Corrected Anomalies in ControlLogix Redundancy Overview 27 Redundancy revision 15 56 corrects the following anomalies Redundancy Revision 15 56 Corrected Anomaly The File Search Compare FSC instruction caused an unrecoverable fault You couldn t send an SLC typed write message to a redundant controller Description The FSC instruction caused a unrecoverable fault if both these conditions occurred e major fault
148. s 4 Make sure the list contains all your keeper capable nodes This includes the CNB modules in the secondary chassis 5 Make sure that each node has a valid keeper signature If the Valid Keeper column shows Yes Then The node has a valid keeper signature No 6 Choose Close See if an Edit Session Isin Purpose Progress Select the node and choose Update Keeper To see if a computer is stopping the secondary chassis from synchronizing Secondary When 42797 Perform this procedure when a secondary chassis won t synchronize and the CNB modules in the secondary chassis show CMPT Publication 1756 UM523F EN P September 2006 112 Maintain and Troubleshoot the System Actions Actions 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 branches of your network until you find the 1757 SRM module in the primary chassis D Right click the SRM and choose Module Configuration 1757 SRM REDUNDANCY MODULE fi Module Info Configuration Synchronization Synchronization Status Event Log Identification Status Vendor Rockwell Automation ae 4 Allen Bradley Major Fault Nol Product Type Redundancy Product 2 Check the recent synch
149. s 1756 PB72 publication 1756 INO78B 1756 PA75R ControlLogix Redundant Power Supply Installation s6PBISR Instructions publication 1756 IN573C Install Modules in the First Redundant Chassis m Set the rotary switches of the 1756 CNB D E or l 1756 CNBR D E modules for both redundant chassis to the same node address 1 Set the rotary switches of each of the 1756 CNB D E or e 1756 CNBR D E modules to the primary node number plus one 42138 For example nodes 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 This is only an example You can install the module in any slot o zo lt ge rw 42799 2 Install a 1756 CNB D E or 1756 CNBR D E module See ControlLogix ControlNet Bridge Installation Instructions publication 1756 IN571 Publication 1756 UM523F EN P September 2006 lt gt gt lt o Install the System 49 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 modules in an
150. s network must be 21 ms or less Y m ControlNet w ControlNet network 1 network 2 d l o m fl Ifthe smallest Then the largest NUT on anyother Ifthe smallest Then the largest NUT on any other NUT onanetwork network must be less than or equal NUT onanetwork network must be less than or equal is ms to ms is ms to ms gt B 21 55 3 17 22 57 4 19 23 59 5 21 24 62 6 23 25 64 7 25 26 66 8 27 21 68 9 29 28 71 0 31 29 73 1 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 September 2006 40 Design the System Plan the EtherNet IP Networks Guideline 1 Use EtherNet IP ONLY for HMls workstations and messaging Follow these guidelines as you plan your EtherNet IP networks Details 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 1 0 modules e peer interlocking produced and consumed tags Important RSLogix 5000 software lets you set up and download a project that tries to use an EtherNet IP network for 1 0 produced tags or consumed tags Those communications don t work however 2 Are communication delays OK during a switchover e
151. s ore 16 1 Power up or undetermined 16 2 Primary with synchronized secondary 16 3 Primary with disqualified secondary 16 4 Primary with no secondary Redundancy state of the PartnerChassis INT GSV lf Then partner chassis RedundancyState 16 8 Synchronized secondary 16 9 Disqualified secondary with primary 16 E No partner Redundancy status of the ModuleRedundancy INT GSV lf Then conmoller State 16 1 Power up or undetermined 16 2 Primary with synchronized secondary 16 3 Primary with disqualified secondary 16 4 Primary with no secondary 16 6 Primary with synchronizing secondary Redundancy state of the PartnerModule INT GSV lf Then parier nedundanoyatale 16 7 Synchronizing secondary 16 8 Synchronized secondary 16 9 Disqualified secondary with primary 16 E No partner Results of the compatibility CompatibilityResults INT GSV lf Then aaa neparne 0 Undetermined 1 No compatible partner 2 Fully compatible partner Publication 1756 UM523F EN P September 2006 172 Attributes of the Redundancy Object For this information Get this attribute Data GSV SSV Description type Status of the Qualification INT GSV If Then synchronization InProgress ae See qualification process 1 Synchronization qualification is not in progress 0 Unsupported 1 99 For modules that can measure their completion percentage the percent of synchronization qualification that is complete 50 For modules that cannot measure their
152. s 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 RM has been connected The partner SRM powered up or become connected by the fiber optic cable The partner RM screamed Publication 1756 UM523F EN P September 2006 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 Event description Transition to Lonely Maintain and Troubleshoot the System 119 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 Unknown Event The SRM configuration tool doesn t have a description for the event WCT time change gt 1 second Export the SRM Event Log Cha
153. s synchronized C Cancel or assemble any test edits D Remove all SFC forces from the project E Make sure that you don t need to make any changes to e 0 Forces Once you start this procedure you won t 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 Publication 1756 UM523F EN P September 2006 146 Maintain and Troubleshoot the System Action 11 Change the project revisions Publication 1756 UM523F EN P September 2006 Details A Go offline ce gt No Edits a M 1 0 Redundancy 53 B Click the Controller Properties button C Change the controller to the newer revision f Controller Properties My_Redundant_Controller Major Faults Minor Faults Date Time Advanced SFC Execution File Redundancy Nonvolatile Memory Memory Serial Port System Protocol User Protocol Vendor Allen Bradley Type 1756 L63 ControlLogix5563 Controller Revision 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
154. s that you just configured Turn on the other chassis Configure the EtherNet IP module in the chassis that is on Do you see the IP address on the front of the module e Ifno then return to step C e f yes then continue with step E Repeat steps 3C and 3D for each EtherNet IP module in this chassis Flash the Modules Redundancy Module 42801 Check Your Installation Install the System 53 1 Turn on the power to one of the redundant chassis 2 Wait for the 1757 SRM module to display PRIM 3 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 4 Turn off the power to the chassis 5 Turn on the power to the second redundant chassis 6 Wait for the 1757 SRM module to display PRIM 7 Flash upgrade each module in the chassis with a compatible revision of firmware Use the same revisions that you used for the first redundant chassis Purpose To make sure that your redundant chassis are able to synchronize When Complete this procedure after you e install the system e configure the communication modules e update firmware Publication 1756 UM523F EN P September 2006 54 Install the System First chassis Second chassis turned on turned on Redundancy M
155. se Module Configuration 1757 SRM REDUNDANCY MODULE E Module Info Configuration Synchronization Synchronization Status Event Log Identification Status Vendor Rockwell Automation General State OK Allen Bradley Major Fault No Product Type Redundancy Product Maintain and Troubleshoot the System 141 Action Details 3 Disqualify the secondary chassis A Click Configuration B Set Auto Synchronization to Never 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log Options Auto Synchronization SRM Serial Number C Choose Apply and then Yes to confirm D Click Synchronization 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log Commands Disqualify Secondary Initiate Switchover Become Eiman 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 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 1757 SRM REDUNDANCY MODULE Pr
156. sertion 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 September 2006 16 ControlLogix Redundancy Overview Can I Use a Network Access Port Do See a Bump in Outputs During a Switchover How Does the Second Controller Stay Up to Date Publication 1756 UM523F EN P September 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 1756 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 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 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
157. ssis 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 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Update Identification Status Vendor Rockwell Automation Allen si OK Bradley Major Fault None Product Type Redundancy Product Publication 1756 UM523F EN P September 2006 144 Maintain and Troubleshoot the System Action Details 5 Disqualify the secondary chassis A Click Configuration B Set Auto Synchronization to Never 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Update Options Auto Synchronization v DAM Serial Number 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 Disqualify Secondary Initiate Switchover E Choose Disqualify Secondary and then Yes The secondary chassis is disq ualified lt Chassis A Primary with Disqualified Secondary Auto a ater F Choose OK A Start the ControlFLASH firmware update tool 6 Update the SRM module in the secondary chassis B Update the 1757 SRM module in the secondary ch
158. ssis B If Timer_RedundancyMSGs DN 1 2 seconds are up so execute the MSG instruction again And ChasB_GetRedundState_FromENBT EN 0 The MSG instruction is not currently enabled Then Execute a MSG 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_RedundancyMSGs DN ChasB_GetRedundState_FromENBT EN MSG Type CIP Generic Message Control ChasB_GetRedundState_FromENBT a R Tag Name Description Alias For Data Type 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 MESSAGE of Chassis B ChasB_RedundancyState Redundancy state of the Chassis B DINT 2 PwOS 3 PwDS 4 PwNS Publication 1756 UM523F EN P September 2006 160 Set Up EtherNet IP Communication Across Subnets Publication 1756 UM523F EN P September 2006 MSG parameter Value Message Type CIP Generic Service Type Get Attribute Single Service Code e Class c0 Instance 1 Attribute 4 Source Element Source Length Destination ChasB_RedundancyState Path Communication tab Specify the 1756 ENBT module in Chassis B Use either of the following methods e Add the module to the 1 0 configuration of the controller T
159. ssis ID Chassis B Chassis B Chassis B Chassis B Chassis A Chassis A 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 Purpose To export specific events from the SRM event log to a CSV or TXT file When Perform this procedure 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 743584 12 2 2004 16 02 27 055 743583 12 2 2004 16 02 27 050 743582 12 2 2004 16 02 26 967 743581 12 2 2004 16 02 26 917 5720 12 5 2004 14 18 43 894 5719 12 2 2004 16 02 27 052 Slot Module Description 2 1756 EWEB 69 Equally Able To Control 5 1757 SRM 1A Chassis Redundancy State chi 2 1756 EVVEB 44 Entered Qualification Phase 4 5 1757 SRM 2E Qualification Complete 5 1757 SRM C Port2 Communication error 5 1757 SRM 1E Chassis Redundancy State ch Publication 1756 UM523F EN P September 2006 120 Maintain and Troubleshoot the System erT Vhen 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
160. st 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 Advanced Redundancy Configuration m Memory Usage Reserve more memory for online addition of If you want to Prevent an incorrect online edit from Indicate whether more of the processor memory that is free after download is to be reserved for online creation of tags or logic Tags Logic Then Do not retain test edits default setting faulting both the primary and secondary controller Keep test edits active during a switchover Retain test edits at the risk of faulting both controllers Publication 1756 UM523F EN P September 2006 Configure and Program the Controller 71 Be Aware That Finalizing Edits Removes Your Original Logic Finalize All Edits in Program MainProgram MainRoutine 5 x lees le salsa 7h Wis el H SSS MyTaq_1 2 MyTaq_1 1 I I j I T T r r MyTag_1 0 MyTag_1 1 1 B 4 gt MainRoutine 4 r 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 s because there s NO original logic to go back to For example the new primary controller can t untest
161. 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 Publication 1756 UM523F EN P September 2006 94 Configure and Program the Controller If Chassis ID Now lt gt Chassis ID Last then Switchover Happened 1 Chassis ID Last Chassis ID 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 Switchover Happened 0 End If Send a Message to the Purpose SRM To let your logic initiate actions in the SRM When 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 September 2006 Configure and Program the Controller 95 Before You Begin Before sending a message to an SRM make sure that e the SRM is configured for program control 1757 SRM REDUNDANCY MODULE Chassis m e the message is unconnected Message Configuration Msqg_1 Lommunication Metod f GIP ft DH Erann Desti el it A y zas 5 7 cle r r Source Liri 4 Destin Source I box clear unchecked ache WonheGiGhs Leave the Conne
162. t e The communication loss is temporary Communications restore themselves Prevention To prevent this situation use series D ControlNet Bridge modules Publication 1756 UM523F EN P September 2006 If You Have Series B ControlNet Bridge Modules 177 Communication Could Stop Situation If You Use a Series B ControlNet Bridge Module 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 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 Prevention To prevent this situation use series D ControlNet Bridge modules Publication 1756 UM523F EN P September 2006 178 If You Have Series B ControlNet Bridge Modules Restriction Description Communication Loss When Bridging You could temporarily lose communication with a remote chassis if you use both these modules in 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 Ese a LICI S j5 IN R 5
163. t Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen Bradley Products Rockwell Software Products and Global Manufacturing Solutions Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Rockwell Automation SA NV Vorstlaan Boulevard du Souverain 36 BP 3A B 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas Rockwell Automation 6040 Ponders Court Greenville SC 29615 4617 USA Tel 1 864 297 4800 Fax 1 864 281 2433 Europe Rockwell Automation Br hlstraRe 22 D 74834 Elztal Dallau Germany Tel 49 6261 9410 Fax 49 6261 17741 Asia Pacific Rockwell Automation 55 Newton Road 11 01 02 Revenue House Singapore 307987 Tel 65 351 6723 Fax 65 355 1733 Publication 1756 UM523F EN P September 2006 PN 953030 15 Supersedes Publication 1756 UM523E EN P May 2005 Copyright 2006 Rockwell Automation Inc All rights reserved Printed in the U S A
164. t 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 11 We recommend that you leave the Memory Usage slider in the middle the default position 12 Choose ox 13 To close the Controller Properties dialog box choose ox Publication 1756 UM523F EN P September 2006 74 Configure and Program the Controller Configure Communications Publication 1756 UM523F EN P September 2006 A redundant system requires some specific configuration choices for successful communications Use this section to perform the following redundancy tasks e Configure I O e Configure produced tags e Configure message MSG instructions e Configure tags for an HMIConfigure I O IMPORTANT For each module in your system make sure that the requested 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 The data DOES NOT update e The logic acts on the last data that it received After the switcho
165. t_Controller 4 Path to the Redundant_Controller redundant controller sonmunication Method GP C DA Chame zj Destination Link gf h Source lir Destination Wade Source os MV Cache Connections e 42977 e ooo Leave this box checked 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 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 P September 2006 Configure and Program the Controller 77 Estimate the Crossload Purpose Time of a Program To estimate the crossload time of a program in a redundant controller When Perform this procedure to gauge the time a project spends crossloading data Before you begin Consideration Details The controller crossloads data at the end of The primary controller stops at the end of every program to crossload fresh data to the every program 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 lt Scan time of program gt Execute program in Crossload results to primary controller secondary controller Start of program End of program The crossload time
166. tag data to be crossloaded measured in 4 byte words Publication 1756 UM523F EN P September 2006 Configure and Program the Controller 79 Minimize Scan Time Action 1 Use a few large programs instead of a lot of small programs To minimize a project s scan time perform the following procedure IMPORTANT Don t 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 Details The controller stops at the end of every program to crossload data So the more programs that you have the more the controller stops to crossload And it often ends up crossloading the same data many times To cut down the number of crossloads A B Use only one or a few programs This is better B E Tasks Big MainTask MainProgram A Program Tags ERI MainRoutine B added_startup B ATR1_51_Get_Data B ATR1_S1_Send_Data B ATR1_53_Process_Data B ATR2_S1_Get_Data B ATR2_S1_Send_Data B ATR2_53_Process_Data E ATRControl B Beacons B CalMerge B Control B Count_Reset B ctrizone_o2 B ctriZone_11 B ctrizone_12 Divide each program into whatever number of routines makes the most sense A routine doesn t cause a crossload Use the main routine of each program to call the other routines of the program If you want to use several tasks
167. trolLogix redundancy system including commonly used terms It also answers some common questions about a ControlLogix redundancy system Topic Page What Are The Main Parts of a Redundant System 13 What firmware combinations make up a redundant system 14 How Do Assign the Primary Chassis 15 What Causes a Switch from One Controller to Another 15 Can Use a Network Access Port 16 Do See a Bump in Outputs During a Switchover 16 How Does the Second Controller Stay Up to Date 16 What If Make Online Edits 18 Does My Scan Time Increase 18 What Happens to Network Addresses During a Switchover 18 What Can t Do with a Redundant System 20 Quick Start Checklists 21 Compatible Software Versions 26 Enhancements to Redundancy Revision 15 56 26 Corrected Anomalies in Redundancy Revision 15 56 27 What Are The Main Parts of The ControlLogix redundancy system uses an identical pair of ControlLogix chassis to keep a machine or process running if a a Redundant System problem occurs with a controller The following diagram shows the layout of a simple redundant setup Publication 1756 UM523F EN P September 2006 14 ControlLogix Redundancy Overview
168. trolNet taps connectors and terminators are connected not completely connected Publication 1756 UM523F EN P September 2006 110 Maintain and Troubleshoot the System Update a Keeper Signature Secondary 42797 Publication 1756 UM523F EN P September 2006 Purpose To see if the keeper signature of a CNB module is stopping the secondary chassis from synchronizing When Perform this procedure when a secondary chassis won t synchronize and its CNB modules show CPT Before You Begin The secondary chassis won t synchronize if the keeper signature of a CNB module doesn t 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 1 Start RSNetWorx for ControlNet software 2 Has this network been scheduled before If Then No A From the File menu select New B From the Network menu select Online C Select your ControlNet network and choose OK Yes A From the File menu select Open B Select the file for the network and choose Open C From the Network menu select Online 3 From the Network menu choose Keeper Status Maintain and Troubleshoot the System 111 4 5 Keeper Capable Node Active Keeper Valid Keeper offline file N A N A 01 No No 02 Yes Ye
169. ts 35 Check Connection Requirements 37 Plan the ControlNet Networks 37 Plan the EtherNet IP Networks 40 Additional Considerations 43 Publication 1756 UM523F EN P September 2006 30 Design the System Lay Out the System ControlLogix Redundancy Requirements and Recommendations Use separate networks for unscheduled and scheduled communication Unscheduled 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 1 0 produced consumed tags use a ControlNet network Scheduled Communication ControlNet L For unscheduled communication use 4 PanelView terminals per va o controller ControlNet network H Multiple redundant chassis e Set NUT 80 ms pairs are OK e Set RPls 375 ms e f multiple ControlNet networks set NUTs a Specified values i Remote location for all T m 4 e 1 0 a e DNB DHRIO amp MVI a communication modules bo C E p DJ M Assign the lowest node numbers N N NI HIV to nonredundant nodes B 1 0 modules Bl Bl RII To connect a computer to the network via an
170. ue of the chassis ID the ID of this chassis Chassis_ID_Last DINT S FS MOV Move Source Chassis_ID_Now 16 Dest Chassis_ID_Last 1 If the chassis ID changes a switchover happen ed 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 EQ Switchover_Happened Not Equal Source 4 Chassis_ID_N a A MOV Move Source Chassis_ID_Now 16 Dest Chassis_ID_Last 1 Source B Chassis_ID_Last 1 Continued on next page Publication 1756 UM523F EN P September 2006 Configure and Program the Controller 93 If Switchover_Happened on then Execute the instructions that you want to execute after a switchover Turn off the Switchover_Happened bit Put your instructions here Switchover_Happened i Switchover_Happened Example 2 Structured Text comment Get the ID of the primary chassis comment comment That s always the chassis that runs the code comment Store the ID in Chassis_ID_Now Chassis_ID_Now DINT code GSV REDUNDANCY PhysicalChassisID Chassis ID Now f this is the first scan Then set the last value of the chassis ID the ID of this chassis Chassis_ID_Last DINT If S FS then Chassis ID Last Chassis ID Now End If If the chassis ID changes a
171. unication between the pair of redundant chassis In a redundant system the following terms describe the relationship between the two redundant chassis Description The controller that is currently controlling the machine or process Primary Chassis The chassis that contains the primary controller or controllers Secondary Controller 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 Secondary Chassis The chassis that contains the secondary controller or controllers Switchover How Do I Assign the Primary Chassis What Causes a Switch from One Controller to Another Transfer of control from the primary controller to the secondary controller After a switchover the controller that takes control becomes the primary controller Its partner controller the controller that was previously the primary controller becomes the secondary controller In a pair of redundant chassis the first chassis turned on becomes the primary chassis When to the secondary chassis receives power it chassis synchronizes itself with the primary chassis When primary chassis components fail control switches to the secondary controller A switchover occurs for any of the following reasons e any of the following situations in the primary chassis loss of power major fault of the controller removal in
172. unication for up to 1 ms at a time and then resumes the continuous task The following table shows the ratio between the continuous task and unscheduled communication at various system overhead time slices Atthis time slice The continuous task And unscheduled runs for communication occurs for up to 10 9 ms 1 ms 20 4 ms 1 ms 33 2 ms 1 ms 50 1 ms 1 ms At a system overhead time slice of 20 default unscheduled communication occurs every 4 ms of continuous task time for 1 ms Legend EE 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 Continuous task E G M M M Publication 1756 UM523F EN P September 2006 Maintain and Troubleshoot the System 125 If you increase the system overhead time slice to 33 unscheduled communication occurs every 2 ms of continuous task time for 1 ms 1ms 1ms 1ms 1ms 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 task E E E HE HEHEHEHEHE Enter a System Overhead Time Slice To change the system overhead time slice Offline 1 F RUN E No Forces b M Ok BAT No Edits F i0 1 On the Online toolbar click controller properties button 2 Click Advanced 2 General Serial Port System Procol User Protocol Major Faults Minor Faults Date Time Advanced SFC Execution File Memory Used Unus
173. ver 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 Configure and Program the Controller 75 Produced tag To the controller with the consumed tag this is the remote CNB module Redundant chassis C S N BI M Zar Eri wa N Data Consumed tag Remote chassis w zZz oOo x Zann In the 1 0 configuration of this controller select a communication format of None for the remote CNB module Publication 1756 UM523F EN P September 2006 76 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 Redundan
174. w to store a project see Logix5000 Controllers 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 Load a Project User Initiated 1 N Se 4 Disqualify the secondary chassis Go online to the primary controller In the primary controller load the project For step by step procedures on how to 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 September 2006 Maintain and Troubleshoot the System 139 Store a Project to Complete the following procedure to store an updated project and Nonvolatile
175. were in a good state 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 branches of your network until you find the 1757 SRM module in the primary chassis D Right click the SRM and choose Module Configuration 1757 SRM REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log Identification Status General State nk 2 Go to the event log Click Event Log 1757 SRM REDUNDANCY MODULE ioj xj Module Info Configuration Synchronization Synchronization Status Event Log OFF OPEN CLOSE Export Selection Auto Update Partner Log Chassis Event Log Time Slot Module Description Classification 5302 11230 2004 09 36 27 929 2 1756 EWEB _ 69 Equally Able To Control State Changes rane 44 IRA AAAA AA AA As An m aoro am Publication 1756 UM523F EN P September 2006 Maintain and Troubleshoot the System 121 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 1757 SRM REDUNDANCY 40DULE p oj x Module Info Contig 1 Synchronization Sy
176. wing professions who design and develop applications that use ControlLogix controllers e Software engineers e Control engineers e Application engineers e Instrumentation technicians Use this manual throughout the lifecycle of a redundancy system The lifecycle consists of the following stages e Design e Installation e Configuration e Programming e Testing e Maintenance and troubleshooting 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 In this manual some text is formatted differently Text That Is Identifies For Example Means Italic The actual name of an item that you Right click User Defined Right click on the item that is named see on your screen or in an example User Defined Courier Information that you must supply Right click You must identify the specific program in based on your application a name of program your application Typically it is a name or variable variable that you have defined Enclosed in brackets A keyboard key Press Enter Press the Enter key Publication 1756 UM523F EN P September 2006 Related Documentation This table lists ControlLogix products and documentation that may be valuable as in programming an application
177. x5562 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 7 connections for redundancy 31 5 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 6 below Publication 1756 UM523F EN P September 2006 ControlLogix Redundancy Overview 23 Redundant Chassis Configuration Continued where Maximum scan time is the maximum scan time for the entire task when the secondary controller is synchronized Parameter Criteria Page e Which modules do you want to use 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 modules in each redundant chassis within these limits lf you have Use up to 1 ControlNet module 2 EtherNet IP modules 2 ControlNet modules 2 EtherNet IP modules 3 ControlNet modules 2 EtherNet IP modules 4 ControlNet modules 1 EtherNet IP module 5 ControlNet modules No EtherNet IP modules Don t use more than 5 ControlNet modules
178. y controller until the program finishes e If a switchover occurs during the program the secondary controller repeats the scan using the same starting data Publication 1756 UM523F EN P September 2006 Configure and Program the Controller 89 Use UID and UIE Instruction Pairs Bound critical rungs with UID and UIE instruction pairs This prevents the higher priority task form interrupting the scan dependent logic as shown below ID gt CTU scan_count CU Count Up U Counter scan_count h gt Preset 1000 Accum 0e EQU Equal Source A scan_count ACC pe Source B 1000 lt UIE gt Buffer Critical Data The following example shows the use of a buffer together with a BSL instruction P 2 2 y l co BSL CPS Copy File Bit Shift Left Synchronous Copy File Source array 0 Array array_buffer 0 Source array_buffer 0 Dest array_buffer 0 Control BSL Dest array 0 Length 2 Source Bit input_bit Length 2 Length 64 photoeye 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 September 2006 90 Configure and Program the Controller Determi
179. y slot lt t oo LICE S TS T 5ININ R 5 B B M T 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 max 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 IN092 Publication 1756 UM523F EN P September 2006 50 Install the System Install Modules in the Second Redundant Chassis a wR n LIC JE S a LI CTE S EN 5I NIN R 5 NIN R 51B B M 5 BIB M T T L_ gt ae 2 3 L_ YY 42800 3 IMPORTANT e The modules in each redundant chassis must match each other IMPORTANT ioios 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 the following fiber optic cables to the 1757 SRM modules
180. y than a unique tag for each chassis If Timer_RedundancyMSGs DN 1 2 seconds are up And ChasA_IsPrimary 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 Timer_RedundancyMSGs DN Publication 1756 UM523F EN P September 2006 Chas4_IsPrimary lt lsPrimary 0 gt Chas4_MSG EN Message Control MSG Type CIP Data Table Read ChasA_MSG E h gt A gt Send the Message to the Appropriate Controller Set Up EtherNet IP Communication Across Subnets 163 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 ChasB_IsPrimary Timer_RedundancyMSGs DN lt lsPrimary 1 gt ChasB_MSG EN p MSG Type CIP Data Table Read Message Control ChasB_MSG E t R Tag Name Description Alias For Data Type ChasA_IsPrimary If set 1 then Chassis A is the primary chassis IsPrimary 0 BOOL ChasA_MSG Message instruction that transfers data between this MESSAGE controller and the controller in redundant Chassis A ChasB_IsPrimary If set 1 then Chassis B is the primary chassis IsPrimary 1 BOOL ChasB_MSG Message instruction that transfers data between this MESSAGE controller and the controlle

ControlLogix Redundancy System

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