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ControlLogix Enhanced Redundancy System User Manual

1. Primary Chassis Primary Chassis a Loginss63 Redundancy Module FiherNeti P ControiNet a Lannea Redundancy Module EtherNet P ControiNet Toma ue TR ToT o ToT Allen Bradley rover PRIM PwQ Allen Bradey CI pem aman PRIM PwDq BAT oo i 3 sa E aa a poof nn CH2 CH1 OK ne Ret oe AREY i ch2 cht ok die fet oe ATED OK i N oO N oc Lo N g Lo N Ey an um 5 oc o E Rel ee oO ee W x S 2 z 8 3 2 N N Ss gt N Le L KCN U Secondary Chassis Secondary Chassis C a Fae Redundancy Module Ee ControiNet aasia Redundancy Module Ener A wE me crower SYNC a ox boo Boab 4 CH2 CHI OK So mE ma AYER OK TA K N KE oc N oc ec wi oO J fra O te wW o co t x x ie iQ 8 kj 2 S N N rs N N L Z C L Rockwell Automation Publication 1756 UM535D EN
2. 1756 RM A or 1756 RM B Module 1756 RMXT Module Top View Top View oa Front View ni UIC i Status Indicators Front View T Status Indicators A i Module A CO OOOO N Ml L A oe yA Aas E L E L E we E Side View CEES L Side View E CS C CN SS C_N Xx a 1 TIS L l C A 2 A A A X J no LC Single LC Singhs mode A lofto E Backplane say ON LS Connector Connector Connector ackplane es Sills Connector 62 Bottom View 44487 Bottom View 31941 M To install the redundancy module follow these steps 1 Align the circuit board with top and bottom guides in the chassis 2 Slide the module into the chassis making sure the module backplane connector properly connects to the chassis backplane The module is properly installed when it is flush with other installed modules IMPORTANT To remove the module push on the locking clips at the top and bottom of each module and slide the module out of the chassis
3. Chassis A Primary with Synchronized Secondary CH1 Status Active CH2 Status Redundant Futo Synchronization State Aways Chassis Platform Configuration Enhanced OK Help Save System Event History If you want to save the system event log to the nonvolatile memory of the redundancy module click Save System History at the bottom of the System Event tab Saving this history can assist with troubleshooting the system at a later time Rockwell Automation Publication 1756 UM535D EN P November 2012 137 Chapter6 Configure the Redundancy Modules Using Dual Fiber Ports with the 1756 RM2 A Redundancy Module The dual fiber ports of the 1756 RM2 A module constitute a redundant pair of communication channels between the partner 1756 RM2s in a redundant chassis pair One of the channels is termed as ACTIVE while the other channel is termed as REDUNDANT All data communication between the partner redundancy modules is conducted exclusively over the ACTIVE channel If or when the ACTIVE channel fails a Fiber Channel Switchover is initiated automatically and all data communication shifts to the REDUNDANT channel which then becomes the new ACTIVE channel Fiber Channel Switchover Due to the fiber channel switchover the redundant chassis pair continues to remain synchronized even in the event of a failure of the ACTIVE channel Any of the following failures of the ACTIVE channel triggers an automatic fi
4. EtherNet IP Switch Redundant Chassis Pair 1756 EN2T 1756 EN2TR 1756 EN2TR 1756 EN2TR 1756 EN2TR mL I734 AENTR F PowerFlex 1756 IB16ISOE 1756 IB161SOE 1756 0B16D 11756 EN2TR w e 1715 Redundant 1 0 1756 ControlLogix 1 0 1734 POINT 1 0 PowerFlex Drive Connected via 1783 ETAP 26 Rockwell Automation Publication 1756 UM535D EN P November 2012 Design an Enhanced Redundancy System Chapter 2 This graphic shows an example ControlLogix enhanced redundancy system revision 19 053 or later that uses ControlNet networks Figure 2 Example ControlLogix Enhanced Redundancy System Revision 19 053 or later Usinga ControlNet Network Workstation SSE oo EB so gt es EtherNet IP Switch Redundant Chassis Pair aE al S N 1756 L75 S 1756 CN2R 1756 RM2 1756 CN2R 1756 CN2R 1756 CN2R 1756 EN2T 1756 CN2R 1756 RM2 1756 CN2R 1756 CN2R 1756 EN2T 1756 CN2R 1756 L75 1734 POINT 1 0 PowerFlex 700S drive connected via 1788 CNCR card 1756 ControlLogix 1 0 may 8888 ododo alll iL 1734 ACNR 1756 CN2R 1756 CN2R PowerFiex 1756 IB16D 1
5. Task Priority 1 s NG regan een New Primary Crossload Crossload Switchover k Priority 2 PIAI Task Priority 2 reer vet Higher priority Task Lower priority eee Sree c ees Tak eanes c as a ees ee ee eee The diagram below shows a lower priority task that has not been completed and a switchover occurs The lower priority task and programs are executed from the beginning and not at the program where the switchover occurred This is because the crossloads and synchronization points were not configured to occur at the end of each program Figure 37 Periodic Task Execution After Switchover When Configured Not to Crossload After Programs en E a a E a E S a E E Task Priority 1 Program 1 Program 2 Program 3 Task Priority 2 D Crossload Program1 Program2 Program3 Task Priority 1 Program 1 Program2 Program 3 Task Priority 2 Program 1 Progra Higher priority _ 9 _ _ Lowerpriority _Creslead Task Interupts Task Resumes Cresslead For more information about programs and tasks with controllers see the Logix5000 Controllers Tasks Programs and Routines Programming Manual publication 1756 PM005 148 Rockwell Automation Publication 1756 UM535D EN P November 2012 Crossloads and Scan Time Program the Redundan
6. An Equal To instruction uses the accumulated scan_count value as a reference to turn on an indicator when the thousandth sc is complete Scan_Count_Light UIE Qu Equal Source A scan_count 4cc 0 1000 Source B For more information about UID and UIE instructions see the Logix5000 Controllers General Instructions Reference Manual publication 1756 RM003 162 Rockwell Automation Publication 1756 UM535D EN P November 2012 Program to Optimize Task Execution Program the Redundant Controller Chapter 7 To make synchronization crossloads and HMI updates as fast as possible make adjustments to the System Overhead Time Slice and the type of tasks used These adjustments affect service communication tasks that take place during the time when the continuous task is not executing This table lists some of the communication that takes place during an continuous task and service communication periods Table 26 Communication Tasks during Scheduled and Unscheduled Periods During These types of communication occur Task execution Update 1 0 data not including block transfers Produced consumed tags Service Communication with programming devices for example RSLogix 5000 software communication Communication with HMI devices Execution of Message MSG instructions including block transfers Responses to messages from other controllers Synchronization of the red
7. IMPORTANT Please note you must be physically present at the location where the redundant chassis are located to do this upgrade IMPORTANT You can only upgrade from firmware revision 19 052 or later to firmware revision 20 054 These steps apply when upgrading from firmware revision 19 052 or later to firmware revision 20 054 Before starting the following steps complete steps 1 5 on page 250 If your system is controlling a process and using rotary switches follow these steps 1 Set the mode switch of the primary and secondary controllers to REM If the redundant controllers in both chassis of the redundant chassis pair are not in Remote Program REM mode the redundancy firmware upgrade cannot be completed 2 Open RSLinx Classic software and browse to the redundancy module 3 Right click the redundancy module and choose Module Configuration H Af 00 1756 L75 LOGIXSS75 1756 L75 A LOGIXSS75 01 1756 RM 1756 RM B REDUNDANCY Nap 02 1756 EN2T 1756 EN2T A Remove Ef 192 168 1 42 1756 EN2T 1756 EN2T A Backplane 1756 A4 4 f 00 1756 L75 LOGIX5575 1756 L75 4 LO 01 1756 RM 1756 RM B REDUNDANCY M 02 1756 EN2T 1756 EN2T A Security eS 4B_VBP 1 1789 A17 4 Virtual Chassis Device Properties Module Configuration Driver Diagnostics Configure Driver Upload EDS file from device 4 Click the Configuration tab Rockwell Automation Publication 1756 UM
8. TIP Ifthe keeper signatures of partnered ControlNet modules are different your redundant chassis may not synchronize Ifthe keeper signatures of your partnered ControlNet modules are different update the keepers of the redundant ControlNet modules Save the Project for Each Primary Controller After you have scheduled your ControlNet networks go online with each controller in your primary chassis and save the project This makes downloading a project easier in the future because you won t be required to reschedule the network after completing the download Automatic Keeper Crossloads The 1756 CN2 B 1756 CN2R B and 1756 CN2RXT ControlNet modules have an Automatic Keeper Crossload feature that makes replacing a ControlNet module in a redundant chassis easier The Automatic Keeper Crossload feature also reduces the need to use RSNetWorx for ControlNet software once the system is running With the Automatic Keeper Crossload feature ControlNet modules can automatically upload the keeper signature and network parameters from the active keeper of a ControlNet network 102 Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the ControlNet Network Chapter 5 To replace a ControlNet module that has been configured and scheduled on the ControlNet network remove the existing module and insert a 1756 CN2 B 1756 CN2R B or 1756 CN2RXT module The module you are inserting must be unconfigured or have a keeper
9. 1O TEE 0 BE eee Se a gat Py Seo 44 0 68 Rockwell Automation Publication 1756 UM535D EN P November 2012 Power Supply indicator is green m E Install the Enhanced Redundancy System Chapter 3 3 Wait for the redundancy module to complete its start up scroll messages Check Module and status indicators Wait 45 seconds before you begin updating the 1756 RM firmware During this time the redundancy module conducts internal operations to prepare for an update Alphanumeric Display Redundancy Module NN mi NEN EANA N AN N A ooo CH2 CH1 OK a e ooo OK indicator is red during self test and turns green if firmware is already E downloaded EFS TIP If it is a new module wait until APPLICATION UPDATE REQUIRED is displayed The status indicator flashes red 4 Launch ControlFLASH software and click Next to begin the update process Rockwell Automation Publication 1756 UM535D EN P November 2012 69 Chapter3 Install the Enhanced Redundancy System 5 Select the module s catalog number upgrade the redundancy module first and click Next IMPORTANT _ The 1756 RM2 A module uses different firmware than the 1756 RM and 1756 RMXT modules Catalog Number Enter the catalog number of the target device fi 7
10. 2 Either click Primary or Secondary depending on the controller you are online with Rem Prog i E Program Mode Dimai EEE gt Controller OK j Battery Fault Controller No Edits a i atery Fau 1 0 Not Present D Sec Prog m r Program Mode re Secondary No Forces E Controller OK Controller mE Battery Fault No Edits a F 0 Not Present D i The redundant controller ID and status are displayed Rem Prog fi Chassis B No Forces Le No Edits a Module Primary with Synchronized Primary E Secondary Rockwell Automation Publication 1756 UM535D EN P November 2012 201 Chapter9 Troubleshoot a Redundant System 3 If further information is required click Controller Properties Rem Prog ta Chassis B gt No Forces b PRIM No Edits a Module Primary with Synchronized p Primary E Secondary LN 4 Click the Redundancy tab General Serial Port System Protocol User Protocol Major Faults Minor Faults Date Time Advanced SFC Execution File Redundancy Nonvolatile Memory Memory M Redundancy Enabled m Redundancy Status Chassis Id B Chassis State Primary with Synchronized Secondary Module State Primary with Synchronized Secondary Module Compatibility Fully Compatible Partner Partner Status Partner Minor Faults Mode Program Powerup Watchdog Key Switch Position Remote
11. After the switchover is complete system synchronization can take longer in an enhanced redundancy system revision 19 052 or later that uses CIP technology than one that does not If you attempt to use the Redundant System Update RSU feature to update an enhanced redundancy system revision 16 081 or earlier that uses Coordinated System Time CST the enhanced redundancy system revision 19 052 or later does not permit a locked switchover and the update fails to complete To work around this restriction first disable CST Mastership in the original redundancy system and then use RSU to update to enhanced redundancy system revision 19 052 or later Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the EtherNet IP Network Chapter 4 This figure shows an example enhanced redundancy system revision 19 052 or later using CIP Sync technology Use of ControlNet is not required when using CIP Sync technology in an enhanced redundancy system It is included in this figure for example purposes Figure 20 Enhanced Redundancy System Revision 19 052 or later Using CIP Sync Technology Supervisory Stratix 8000 CIP Sync Primary Chassis 5 EET C ES ptic Cable EtherNet GM Grandmaster time source M Master S Slave P1 and P2 Priorities Rockwell Automation Publication 1756 UM535D EN P November 2012 83 Chapter4 Configure the EtherNet IP Network Use Produce Consume B
12. Memory Usage Slider co ea Rockwell Automation Publication 1756 UM535D EN P November 2012 185 Chapter 7 186 Program the Redundant Controller Finalize Edits with Caution When you finalize edits to your program while online the original program that existed before the changes were made is deleted As a result if the edits you finalize cause a fault on the primary controller the new primary controller will also fault after the switchover Before you finalize any edits to your program test the edits to verify that faults do not occur Figure 57 Test Edits Before Finalizing Test Pending Edits Finalize All Edits sled ied wile Mad A AADAAAATA ACKHMI COMMONBITS O 2 es TIP TON Timer On Delay Timer POWERUP_TIMER lt COMMONTIMER 0 Preset 0 Accum 500 TON Timer On Delay Timer POVYERUP_TIMER COMMONTIMER O gt Preset 0 Accum 500 EN ON EN DN Even if you have not enabled the Retain Test Edits on Switchover property faults can still occur on the primary and secondary controllers if the edits are finalized The Retain Test Edits on Switchover property affects only edits that are being tested The Retain Test Edits on Switchover does not affect the redundant controllers that are running finalized edits Rockwell Automation Publication 1756 UM535D EN P November 2012 Program the Redundant Controller Chapter 7 Reserve Memory for Tags and Logic Dep
13. Updated system checklists 1 Subsequent to revision B of this manual s release the revision 19 052 firmware was replaced with revision 19 053 firmware for the 1756 L7x controllers Rockwell Automation Publication 1756 UM535D EN P November 2012 285 AppendixG Enhanced Redundancy Revision History Notes 286 Rockwell Automation Publication 1756 UM535D EN P November 2012 Numerics 1715 Redundant 1 0 systems 16 18 35 44 1756 A7XT 24 1756 CN2 B 56 1756 CN2R B 56 1756 CN2RXT 56 1756 CN2x modules 32 1756 EN2F 24 242 1756 EN2T 56 sockets 85 1756 EN2TR 56 sockets 85 1756 EN2Tx modules 32 1756 EN2TXT 56 1756 L6x 279 1756 L6x controller 29 1756 L7x 30 185 279 1756 RM2 A 152 1756 L7x controller 29 1756 L7xXT 25 1756 RM status indicators 200 1756 RM and 1756 RMXT modules 31 1756 RM2 A 24 57 61 1756 L7x 152 compatible revisions 24 crossload 151 dual fiber ports 138 restrictions 22 RMCT 54 status indicators 200 227 1756 RM2xXT A 24 57 61 compatible revisions 24 restrictions 22 status indicators 227 A Array File Shift instructions 159 Auto Synchronization 114 beacon 88 BOOTP DHCP utility 86 C calculate task watchdog 177 CH1 status indicators 229 CH2 status indicators 229 Index chassis 52 55 designate 71 ID 115 install 54 55 module placement 54 primary 19 redundant 24 secondary 19 chassis configuration list 277 CIP Sync technology 1
14. If you need to reduce the CPU usage of your ControlNet modules consider making the changes described in this list Increase the Network Update Time NUT of the ControlNet network e Increase the Requested Packet Interval RPI of your connections e Reduce the amount of connections through the ControlNet modules e Reduce the number of messages used in the program Connections Used If your ControlNet modules connections used are near the limits of the module you may experience difficulty when attempting to go online with the system or when attempting to add modules to the system For information about connections available with ControlNet modules see ControlNet Network Requirements on page 38 Monitor the ControlNet Network For most redundant applications monitoring the status of the ControlNet network is important for maintenance and troubleshooting purposes For programming samples to monitor the ControlNet network visit the Rockwell Automation Sample Code Library at http samplecode rockwellautomation com Applicable sample programs include the following e ME Faceplates for ControlNet Diagnostics e ControlNet Connection and Media Status Rockwell Automation Publication 1756 UM535D EN P November 2012 Chapter 9 Troubleshoot a Redundant System Topic Page General Troubleshooting Tasks 199 Check the Module Status Indicators 200 Use RSLogix 5000 Software to View
15. Recovery Method Verify that these conditions exist e A partner chassis is connected e Power is applied to both redundant chassis e Partnered controllers have the same Catalog number Slot number Firmware revision 33 An unpartnered controller has been identified in in the new primary chassis after a switchover Use either of these methods e Remove the unpartnered controller and troubleshoot the cause of the switchover Adda partner controller to the secondary chassis troubleshoot the cause of the switchover and synchronize the system 34 Prior to switchover a mode switch mismatch was present The old primary controller was in Program mode and its secondary partner s mode switch was in the Run position Instead of the switchover transitioning the new primary controller to go to Run mode the new primary controller transitions to a faulted state after the switchover Use either of these methods Change the mode switches from Run mode to Program mode and back to Run mode twice to clear the fault Make sure that the mode switch positions for both controllers in a partnered set match Use RSLogix 5000 to go online with the controllers Then clear the faults and change the mode switch positions for both the controllers in the partnered set to Run Rockwell Automation Publication 1756 UM535D EN P November 2012 203 Chapter9 Troubleshoot a Redundant System Use the RMCT for
16. SFP Error Message Use only Rockwell Automation approved small form pluggable SFP When an incompatible SFP is installed in the 1756 RM2 A module the CH1 CH2 status indicator shows solid red and the RMCT software displays the following error message in the status bar at the bottom of the screen SFP Cpt 1756 RM A and 1756 RM B Status Indicators Figure 68 Redundancy Module Status Indicators for 1756 RM and 1756 RMXT Modules Module Status Display REDUNDACY MODULE PIRIM Module Status Display COI CIC Status Indicators PRI COM OK The module status display provides diagnostic information Table 43 Module Status Display Module Status Display Description Four character display executing self test at powerup No action necessary TXXX The redundancy module is executing a self test at powerup xxx represents a hexadecimal test identification number Wait for self test to finish No action required XFER Application firmware update is in progress Wait for firmware update to finish No action is required ERAS Boot mode Erasing current redundancy module firmware 230 Rockwell Automation Publication 1756 UM535D EN P November 2012 Status Indicators Appendix A Table 43 Module Status Display Module Status Display Description PROG Boot mode Updating redundancy module firmware Wait for firmware update to f
17. You can configure two beacon related parameters e Beacon interval Frequency at which the active ring supervisor transmits a beacon frame through both of its ring ports e Beacon timeout Amount of time that supervisor or ring nodes wait before timing out the reception of beacon frames and taking appropriate action IMPORTANT Although these two parameters are configurable the default values accommodate most applications We strongly recommend that you use the default values 88 Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the EtherNet IP Network Chapter 4 During normal operation one of the active supervisor node s network ports is blocked for DLR protocol frames However the active supervisor node continues to send beacon frames out of both network ports to monitor network health The graphic below shows the use of beacon frames sent from the active ring supervisor Figure 23 Normal DLR Network Operation Active Ring e Supervisor Blocked Port Beacon Frame Beacon Frame ___ _ ___ gt a a Control Traffic Control Traffic z0 go BED i agit fao weed ge Be fixe need Ring Node 4 Ring Node 1 Ring Node 2 Ring Node 3 Rockwell Automation Publication 1756 UM535D EN P November 2012 89 90 Chapter4 Configure the EtherNet IP Network Thi
18. 14 Enter Qualification Phase 4 Qualifical 178 11 11 2010 13 54 00 652 1 1756 CN2R 21 Equally Able To Control State Ch 177 11211 2010 13 54 00 6511 1756 CN2R 14 Enter Qualification Phase 4 Qualifical 6 Click Export Selection Export Selection The Export Event Log dialog box opens 7 Complete these steps on the Export Event Log dialog box a Specify a file name and location or use the default name and location b Check CSV Comma Separated Value TIP If you are sending the exported Event Log files to Rockwell Automation Technical Support you must use the CSV file type c Check Include Extended Information TIP If you are sending the exported Event Log files to Rockwell Automation Technical Support include the diagnostic data and extended information If you include this data Rockwell Automation Technical Support can analyze module and system failures more effectively Rockwell Automation Publication 1756 UM535D EN P November 2012 125 Chapter 6 126 Configure the Redundancy Modules 8 Click Export Export Event Log E File name C 1642218_chassis 11162010_1641 csv Browse File Type Text CSV Comma Separated Value Export Diagnostic Data IV Include Extended Information Cancel The event log is exported The log can take a few minutes to export Exporting event logs from the RM in chassis A 41 i RM log export in progress for Chassis amp RM Loss of Cha
19. 5 Set the redundancy module date and time according to your preference 6 Click OK 7 Close the RMCT Your redundant system firmware upgrade is now complete Rockwell Automation Publication 1756 UM535D EN P November 2012 263 AppendixC Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Repla ce 1756 RM A or 1756 If you need to replace your current redundancy modules with 1756 RM2 A RM B Redundan cy Modules modules you can do so without initiating a switchover with 1756 RM2 A Redundancy Modules TIP For the following steps redundancy module is used when referring to the 1756 RM A or 1756 RM B modules Before executing these steps review the most recent Redundancy Bundle release notes to determine the 1756 RM2 firmware revision and RMCT version needed You can find this information at the Product Compatibility and Download Center at http www rockwellautomation com support downloads html 1 10 11 12 13 14 15 Install the compatible version of the RMCT software You must shut down RSLinx Classic software to perform the installation and then restart RSLinx Classic software after the installation is complete Set the Auto Synchronization option in the Configuration tab of the RMCT to Never Using the RMCT disqualify the redundant chassis pair if not already disqualified Unplug the fiber cable on both of the redundancy modules Close
20. 66 Rockwell Automation Publication 1756 UM535D EN P November 2012 Install the Enhanced Redundancy System Chapter 3 Fiber optic Cable If you choose to make your own fiber optic cables consider the following e Fiber optic Communication Cable Specifications 1756 RM2XT 1756 RM A or 1756 RM B 25 70 C 13 158 F 0 60 C 32 140 F Attribute 1756 RM2 A 0 60 C 32 140 F 1756 RMXT 25 70 C 13 158 F Temperature operating Connector type LC type fiber optic Cable type 8 5 125 micron single mode fiber optic cable Channels 1 transmit and receive fiber Length max 10 km 10 000 m 10936 13 yd 4 km 4000 m 4 374 45 yd Transmission 1000 Mbps Less than or equal to 100 Mbps Wavelength 1310 nm 1300 nm SFP transceiver Transceiver Rockwell PN 91972 Connector cable LC duplex connector 1000BASE LX compliant 1 Longer distances are supported based on the systems optical power budget See the Optical Power Budget Ranges on page 67 e Determine Optical Power Budget You can determine the maximum optical power budget in decibels dB for a fiber optic link by computing the difference between the minimum transmitter output optical power dBm avg and the lowest receiver sensitivity dBm avg The optical power budget provides the necessary optical signal range to establish a working fiber optic link You must account for t
21. A csv and a dbg file is in the folder location specified Make sure to provide both these files to Rockwell Automation Technical Support when troubleshooting an anomaly 128 Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Redundancy Modules Chapter 6 Clear a Fault You can use the Clear Fault feature on the Event Log tab to clear major faults that occur on a redundancy module Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History eo pdate Partner Log ON C OFF C OFEN CLOSE Export Selection Export All Slot Module Na Description Classification f 2010 5 399 7 6 Hardware failure fee era 960716 010 14 13 59 517 Response to Open Bridge Connection Starts Stops 960715 11716 2010 14 13 59 516 1756 RM 2 Request to Open Bridge Connection Starts Stops 960714 11716 2010 14 13 59 496 1756 RM 2 Response to Open Bridge Connection Starts Stops 960713 11 16 2010 14 13 59 496 1756 RM 2 Request to Open Bridge Connection Starts Stops 960712 11 16 2010 14 13 59 476 1756 AM 5 Response to Open Bridge Connection Starts Stops 960711 11 16 2010 14 13 59 476 1756 AM 2 Request to Open Bridge Connection Starts Stops 960710 11 16 2010 14 13 59 456 1756 AM 2 Response to Open Bridge Connection Starts Stops 960709 11 16 2010 14 13 59 456 1756 AM 2 Request to Open Bridge Connection Starts Stops 960708 11 16 2010 14 13 59 436 1756 AM 2 Resp
22. Added memory usage slider Updated information for event log update Added information for Export diagnostics button Added 1756 L71 controller information Added 1756 EN2F module information Added how to upgrade Ethernet modules when rotary switches are set between 2 254 Added how to upgrade from an enhanced redundancy system to another by using RSU Added software version 20 for an enhanced redundancy system Updated chassis configuration list to include 1756 L71 controller and 1756 EN2F communication module Updated information about produced unicast tags Updated information about 1 0 and multicast connections Updated controller checklist to add 1756 L71 controller Updated Watchdog time information Rockwell Automation Publication 1756 UM535D EN P November 2012 Publication Revision and Date 1756 UM535B EN P December 2010 Enhanced Redundancy Revision History Appendix G Topic Updates to EtherNet IP network use in enhanced redundancy systems Support for 1756 A4LXT to chassis Support for 1756 L65 controller Support for 1756 L7x controllers Improved scan time with 1756 L7x controllers when compared to the scan time with 1756 L6x controllers Corrected MSG attribute value to set the date and time for a 1756 RM redundancy module Support for Partial Import online Support for controller logging Updated status indicator information
23. Figure 9 Example of Bridging to Remote 1 0 on Various Networks Workstation HMI Ethernet Switch 1 Primary Chassis Secondary Chassis o gy ma Jes la el oH SHAS HAS oH SHAS HAS DHHEHH Z DAHEHH Z SHHSHH s HHS SHH SHH HH SHH SHAE HAS SHH SHAE Hae Chassis Bridge from ControlNet to Remote mey 0 Networks a Hi s HH HAS Hoe Z 53H05 OHS pos 5 Boos qos Bos gen N N HH N HHHH HH To Universal 1 0 Network To EtherNet IP Network To DeviceNet Network IMPORTANT Cannot bridge to 1 0 modules 42 Rockwell Automation Publication 1756 UM535D EN P November 2012 Design an Enhanced Redundancy System Chapter 2 You can bridge these networks via a remote chassis e ControlNet e DeviceNet e EtherNet IP e Universal Remote I O e Data Highway Plus This table indicates what system components can be used with each network connected to a redundant system Table 8 Communication Networks Available For Use with Enhanced Redundancy Systems Network Connection to Redundant System Component 1 0 HMI ControlNet Directly to redundant chassis Yes Yes Via a bridge No Yes DeviceNet Via a bridge Yes Yes EtherNet IP Directly to redunda
24. IMPORTANT Ifyou are adding redundancy to an already operational ControlLogix system shut off your process to install the redundancy module The first chassis you install the redundancy module into and turn on becomes the primary chassis You can also have to do the following e Use RSNetWorx software to configure keeper information in the secondary ControlNet communication module if the master keeper for ControlNet communication is in the primary chassis e Enable redundancy in RSLogix 5000 software and remove any 1 0 modules from the chassis This completes the installation of the first chassis and its components Chassis power must remain off Rockwell Automation Publication 1756 UM535D EN P November 2012 Step 3 Connect the Redundancy Modules viaa Fiber optic Cable Install the Enhanced Redundancy System Chapter 3 Install the Second Chassis Once the first chassis and its components are installed you can install the second chassis of the redundant chassis pair Complete these tasks as described in the Install the First Chassis and its Components section to install the second chassis e Install the Redundancy Module e Install the Communication Modules e Install a Controller e Install the Redundancy Module IMPORTANT The components used in the first and seand chassis must match exactly for the system to synchronize Once the first and second chassis and their components are installed you connect the redu
25. Redundancy Commands Synchronize Secondary Disquality Secondary Initiate Switchover Become Primary Recent Synchronization Attempts Order Result Abort Module Confiquration Error Abort Module Configuration Error N 2 Success N 3 Abort Module Pair Incompatible Refresh Description module in the chassis returned an invalid response to a Synchronization request 1 See Event Log for Slot Number of Module which rejected qualification 2 Check module confiquration and retry 4 Click the Synchronization Status tab to check the compatibility between modules Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History Complete Module Name Module Revision Secondary Readiness State Compatibility 0 100 1756 L73 4 LOGIX5573 20 54 Synchronized Primary Full 1 lt empty gt 2 100 1756 EN2T 4 5 8 Synchronized Primary Full 3 100 1756 AM2 REDUNDANCY 20 4 Synchronized Primary Full All of the modules are indicated as being fully compatible Rockwell Automation Publication 1756 UM535D EN P November 2012 225 Chapter9 Troubleshoot a Redundant System 5 Open RSLogix 5000 and go online with the primary controller in your system 6 Open the controller properties and verify that Redundancy Enabled is checked zy Controller Properties Controller _ChassisA H o x General Serial Port S
26. The 1715 Redundant I O system lets a controller communicate to a remote redundant I O chassis over an EtherNet IP network The 1715 Redundant I O system provides high availability and redundancy for critical processes by using a redundant adapter pair and multiple I O modules that have diagnostics and are easily replaceable The 1715 Redundant I O system consists of a single two slot adapter base unit that houses a redundant adapter module pair The adapter base unit is connected to up to 8 three slot I O base units that can hold up to 24 fully configurable digital and analog I O modules You can configure a 1715 Redundant I O system in a Ring or Star topology Each 1715 Redundant I O system uses a single IP address as the primary IP address for all communication The redundant adapter module pair consists of two active modules a primary adapter module and its partner a secondary module 44 Rockwell Automation Publication 1756 UM535D EN P November 2012 Design an Enhanced Redundancy System Chapter 2 Figure 10 Example of 1 0 Placement Options Workstation EtherNet IP
27. The Redundancy Module Configuration Tool RMCT is used to configure the redundancy modules and to determine the status of the redundancy system Use the RMCT to complete these configuration related tasks e Set Auto Synchronization parameters e Set the time and date of redundancy modules e View and set module information e View and set Chassis ID parameters Chassis A Chassis B e Lock the redundant system for an update e Conduct a test switchover You can also use this functionality available with the RMCT to determine the redundant system s status e View error diagnostics specific to redundant chassis e View partnered modules qualification and compatibility status e Identify noncompliant modules for removal e View redundant system event history Rockwell Automation Publication 1756 UM535D EN P November 2012 105 Chapter6 Configure the Redundancy Modules Determine if Further Configuration is Required 106 The chassis platform configuration identifies the common operating platform of the modules in the redundant chassis and applies to all redundancy modules It may be one of the following values depending on the redundancy release installed in the system and the type of communication modules running in the redundant chassis Table 16 Chassis Platform Configuration Type Description Standard The redundant chassis is operating on a Standard platform Modules supported in redundancy rel
28. e Set Partnered ControlNet Module Switches to the Same Address e Reserve Consecutive Node Addresses for Partner Modules Use at Least Four ControlNet Network Nodes With redundant systems at least four ControlNet network nodes are required This is because two or more ControlNet nodes must be used in addition to the two ControlNet modules used in the redundant chassis One of the two nodes outside of the redundant chassis must be at a lower node address than the ControlNet modules in the redundant chassis If your ControlNet uses less than four nodes in the event of a switchover connections can be dropped and outputs connected to that node can change state during the switchover You can include these ControlNet modules in addition to redundant ControlNet nodes e ControlNet bridge modules in remote chassis e Any other ControlNet devices on the ControlNet network e A workstation running RSLinx Classic communication software that is connected via a ControlNet network 38 Rockwell Automation Publication 1756 UM535D EN P November 2012 Design an Enhanced Redundancy System Chapter 2 Assign Lowest Node Numbers to Remote ControlNet Modules Do not assign the lowest ControlNet node addresses to ControlNet modules in the redundant chassis pair If you assign the lowest ControlNet node addresses to ControlNet modules in the redundant chassis pair you can experience these system behaviors e Upon a switchover you can los
29. Backplane 1756 A4 4 f 00 1756 L73 LOGIXSS73 NSONL_Example 02 1756 EN2T 1756 EN2T 4 9 oO 214 1756 RM2 REDUNDANCY MODUL 192 168 1 42 1756 ENZT 1756 ENZT A Remove amp Backplane 1756 A4 4 Driver Diagnostics 00 1756 L73 LOGIX5573 NSONL_Example Configure Driver 02 1756 EN2T 1756 EN2T 4 l Upload EDS file from device 03 1756 RM2 4 1756 RM2 REDUNDANCY MODULE Security Device Properties Module Configuration 4 Click the Configuration tab in the RMCT 5 From the Auto Synchronization pull down menu choose Never Module Info Configuration Synchronization Synchronization Status Event Log System Update Syste r Redundancy Module Options Auto Synchronization Always Serial Number Never E Chassis ID Conditional Description 6 Click Apply then click Yes 254 Rockwell Automation Publication 1756 UM535D EN P November 2012 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C 7 Click the Synchronization tab Module Info Configuration Synchronization Synchronization Stat m Redundancy Commands Synchronize Secondary Disqualify Secondary 8 Click Disqualify Secondary then click Yes The secondary chassis is disqualified as indicated by the RMCT at the bottom left of the RMCT and on the redundancy module s status display Status in RMCT Chassis A Primary wi
30. Rockwell Automation Publication 1756 UM535D EN P November 2012 39 Chapter 2 40 Design an Enhanced Redundancy System Reserve Consecutive Node Addresses for Partner Modules Where ControlNet modules are used as partners in redundant chassis plan consecutive node numbers for those partnered modules Plan for consecutive node addresses because the redundant system automatically assigns the consecutive node address to the secondary ControlNet module For example partnered ControlNet modules with address switches set at 12 are assigned ControlNet node numbers 12 and 13 by the system TIP The primary chassis always assumes the lower of the two node addresses Figure 7 Example of Redundant ControlNet Modules at Consecutive Addresses Roe ees O59 2 O91 9 ontrolNet Module Switches Primary Chassis Secondary Chassis ome SW eg ee e oe e EO Ez a eE E RE iso W Lgl io HSA HHS HI Node 12 io HSH HAs HI INode 13 ca zZ Ezi os zm Zz l ft Ww C3 5 b oO co ji ji 7 LO LO co co LO LO co co N N LO LO HI N N Lo HHO X ms Y s Rockwell Automation Publication 1756 UM535D EN P November 2012 Redundant ControlNet Media Design an Enhanced Redundancy System Chapt
31. 0 Serial Port O Key Switch Mismatch Program Battery 5 If controller fault details are needed click the Major Faults and Minor Faults tabs to view fault types and codes Date Time Advanced SFCExecution File Redundancy Nonvolatile Memory Memory General Serial Port System Protocol User Protocol Major Faults Minor Faults 1 minor fault since last cleared Eadie Recent Faults 1 1 1998 1 22 57 AM Fault Bits Type 10 Battery Fault J Powerup Code 10 Battery missing or needs to be replaced yo Program J Watchdog Serial Port Nonvolatile Memory Jv Battery 202 Rockwell Automation Publication 1756 UM535D EN P November 2012 Troubleshoot a Redundant System Chapter 9 6 If necessary reference these resources e Redundant Controller Major Fault Codes e Logix5000 Controllers Major and Minor Faults programming manual publication 1756 PM014 describes all major and minor fault codes Redundant Controller Major Fault Codes The fault codes listed and described in this table are specific to redundant controllers For information about all controller major and minor fault codes see the Logix5000 Controllers Major and Minor Faults Programming Manual publication 1756 PM014 Table 38 Redundant Controller Major Fault Codes Type 12 Code 32 Cause A disqualified secondary controller has had power cycled and no partner chassis or controller was found upon powerup
32. 1756 ControlLogix controllers L73 1756 L74 This components available with enhanced redundancy 1756 L75 systems revision 19 053 or later 1756 L71 ControlLogix controller This component is available with enhanced redundancy systems revision 20 054 or later 1756 L73XT ControlLogix XT controller revision 19 053 or later Power supplies 1756 PA72 1756 ControlLogix AC power supplies PA75 1756 PB72 1756 ControlLogix DC power supplies PB75 1756 PC75 1756 PH75 1756 PAXT 1756 ControlLogix XT AC power supply 34 IMPORTANT PBXT 1756 PA75R ControlLogix AC redundant power supply 1756 PB75R ControlLogix DC redundant power supply 1756 CPR ControlLogix redundant power supply cable 1756 PSCA2 ControlLogix chassis adapter module There are module series level firmware revision and software version requirements for enhanced redundancy systems For more information on these series level firmware revision and version requirements see the current release notes at http rockwellautomation com literature Rockwell Automation Publication 1756 UM535D EN P November 2012 25 Chapter2 Design an Enhanced Redundancy System This graphic shows an example ControlLogix enhanced redundancy system revision 19 053 or later that uses EtherNet IP networks Figure 1 Example ControlLogix Enhanced Redundancy System Revision 19 053 or later Using an EtherNet IP Network Workstation
33. 192 168 1 42 1756 EN2T 1756 EN2T A Remove Backplane 1756 44 4 Driver Diagnostics j 00 1756 L73 LOGIX5573 NSONL_Example Configure Driver 02 1756 EN2T 1756 EN2T A 3 f i Upload EDS file from device 03 1756 RM2 4 1756 RM2 REDUNDANCY MODULE Security Device Properties Lode conrauraton a 4 In the Configuration tab set the Auto Synchronization parameter to Conditional Redundancy Module Options Always v Always Conditional Auto Synchronization Chassis ID Rockwell Automation Publication 1756 UM535D EN P November 2012 179 Chapter7 Program the Redundant Controller On the Synchronization tab click Disqualify Secondary Disqualify Secondary In RSLogix 5000 software access the Controller Properties dialog box and click the Nonvolatile Memory tab Click Load Store 8 Click lt Store and then click Yes When the store is complete we go online with the secondary controller 9 10 11 12 Complete steps 6 8 to store the project in nonvolatile memory of the secondary controller In RSLinx Classic software open the RMCT for one of the redundancy modules in the redundant pair In the Synchronization tab click Synchronize Secondary Synchronize Secondary In the Configuration tab set the Auto Synchronization option to your desired setting 180 Rockwell Automation Publication 1756 UM535D EN P November 2012 Program the Redundant Control
34. A Program Tags A Program Tags MainRoutine H MainRoutine B added_startup B Count_Reset 4TR1_51_Get_ Data B MDS Alarms ATR1_S1_Send_Data E mDs_PLC_Clock ATR1_53_Process_Data B MDS Status ATR2_S1_Get_Data ff SCANTIME_MONITOR ATR2_51_Send_Data ATR_Comms 4TR2_53_Process_Data c3 HLCComms ATRControl E 3 ME_Comms Beacons G Conv CalMerge BE control Count_Reset CtriZone_02 CtriZone_11 CtriZone_12 a a a Lm a a Ly a Rockwell Automation Publication 1756 UM535D EN P November 2012 153 Chapter 7 154 Program the Redundant Controller 12 bytes of data to crossload 4 bytes for each tag 4 bytes of data to crossload Manage Tags for Efficient Crossloads To program for more efficient crossloads of data and to reduce the amount of time required for a crossload to execute manage your data tags as recommended in these sections Delete Unused Tags Deleting unused tags reduces the size of the tag database A smaller database takes less time to crossload Use Arrays and User Defined Data Types If you use arrays and User Defined Data Types the tags use smaller 4 byte 32 bit words for all of the data in the type or array If you create an individual tag the controller reserves 4 bytes 32 bits of memory even if the tag uses only 1 bit Arrays and User Defined Data Types help conserve the most memory with BOOL tags However we also recommend you use them for your SINT INT DINT REAL COUNT
35. Chapter 3 Install the Enhanced Redundancy System North American Hazardous Location Approval The following information applies when operating this equipment in hazardous locations Products marked CL 1 DIV 2 GP A B C D are suitable for use in Class Division 2 Groups A B C D Hazardous Locations and nonhazardous locations only Each product is supplied with markings on the rating nameplate indicating the hazardous location temperature code When combining products within a system the most adverse temperature code lowest T number may be used to help determine the overall temperature code of the system Combinations of equipment in your system are subject to investigation by the local Authority Having Jurisdiction at the time of installation Informations sur l utilisation de cet quipement en environnements dangereux Les produits marqu s CL I DIV 2 GP A B C D ne conviennent qu une utilisation en environnements de Classe Division 2 Groupes A B C D dangereux et non dangereux Chaque produit est livr avec des marquages sur sa plaque d identification qui indiquent le code de temp rature pour les environnements dangereux Lorsque plusieurs produits sont combin s dans un syst me le code de temp rature le plus d favorable code de temp rature le plus faible peut tre utilis pour d terminer le code de temp rature global du syst me Les combinaisons d quipements dans le syst me sont sujettes
36. Lenath b4 CPS Synchronous Copy File eCanay_buffer 0 Dest array 0 Length 2 For more information about BSL BSR FFU COP and CPS instructions see the Logix5000 Controllers General Instructions Reference Manual publication 1756 RM003 Scan dependent Logic If you program a lower priority task so that one instruction is dependent on another instruction that occurs elsewhere in your program your programming may be disrupted by a task interrupt and switchover The disruption can occur because the lower priority task may be interrupted by the higher priority task and then a switchover may occur before the lower priority task is completed When the lower priority task is executed from the beginning by the new primary controller after the switchover the dependent instruction may not execute at the most recent value or state Rockwell Automation Publication 1756 UM535D EN P November 2012 Program the Redundant Controller Chapter 7 For example if a higher priority task interrupts the logic shown in this example the value of scan_count ACC is sent to the secondary controller at the end of the program in the higher priority task If a switchover occurs before the primary controller completes the EQU instruction the new primary controller starts its execution at the beginning of the program and the EQU instruction misses the last value of scan_count ACC As a result any programming that uses the Scan_Count_Light tag may also
37. November 2012 Install the Enhanced Redundancy System Chapter 3 L ATTENTION This equipment is not resistant to sunlight or other sources of UV radiation WARNING rN e This equipment must be installed in an enclosure providing at least IP54 protection when applied in Zone 2 environments e This equipment shall be used within its specified ratings defined by Rockwell Automation This equipment must be used only with ATEX certified Rockwell Automation backplanes e Donot disconnect equipment unless power has been removed or the area is known to be nonhazardous Safety related Programmable Electronic Systems ATTENTION Personnel responsible for the application of safety related programmable electronic systems PES shall be aware of the safety requirements in the application of the system and shall be trained in using the system Optical Ports ATTENTION Under certain conditions viewing the optical port may expose the eye to hazard When viewed under some conditions the optical port may expose the eye beyond the maximum permissible exposure recommendations Small Form factor Pluggable WARNING When you insert or remove the small form factor pluggable SFP optical transceiver while 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 Rockwell Automation Publication 1756 UM535D EN P November 2012 59
38. Rockwell Automation Publication 1756 UM535D EN P November 2012 53 Chapter3 Install the Enhanced Redundancy System Step 2 Install the Hardware IMPORTANT When using the 1756 RM2 A or 1756 RM2xXT module you must use version 8 01 05 or later of the RMCT TIP When the redundancy module firmware is upgraded the RMCT is updated The RMCT automatically uses the version that is compatible with the redundancy module firmware revision installed Add the EDS Files Some modules have the EDS files already installed However if needed obtain EDS files for modules in your system from the Rockwell Automation Support website at http www rockwellautomation com resources eds Once you have downloaded the required EDS file launch the EDS Hardware Configuration Tool by choosing Start gt Programs gt Rockwell Software gt RSLinx Tools gt EDS Hardware Installation Tool The tool then prompts you to Add or Remove EDS files Follow these steps to set up and install your system s hardware components Install the First Chassis and its Components When you install an enhanced redundancy system install one chassis and its necessary components at a time Module Placement and Partnering Each pair of controllers and communication modules must be comprised of compatible partner modules Two modules in the same slot are considered as compatible partners only if they contain compatible hardware and firmware and other rules that can
39. Switch Primary Chassis Secondary Chassis SHHS SHH HHS HASTA SHAS SHS HAHA S HAS HH SHAS HS PE i PE pa n PEN ma LA n m DENA IH PENSE De EHE SHESFHS HASH SE AS Bridging Chassis g O ma EL dS S a S HHS HHS HHS a E 2 HH Haz HHS IR SHAS ono HHS 8 Ho sone dys SAR BBS aS 1734 POINT 1 0 1715 Redundant 1 0 ControlNet DeviceNet Device 1771 Chassis with Control Tower 1771 ASB Universal Remote 1 0 DeviceNet Rockwell Automation Publication 1756 UM535D EN P November 2012 45 Chapter2 Design an Enhanced Redundancy System Using HMI 46 Depending on the network used to connect the redundant system to HMIs plan for certain placement and configuration requirements You can connect an HMI to a primary chassis over either of these networks e EtherNet IP e ControlNet HMI Connected via an EtherNet IP Network This table describes redundant system considerations specific to the HMI being used on the EtherNet IP network Type of HMI Used PanelView Standard terminal Considerations Same as a nonredundant system PanelView Plus terminal VersaView industrial computer running a Windows CE operating system e Use RSLinx Enterprise software version 5 0 or later e Set aside connections for each PanelView Plus or VersaView CE terminal as indicated in this table In this module Reserve Controller 5 connections 1756 EN2T 5 connections FactoryTalk View Supervisory Edition softwa
40. Synchronization Attempts and Status When troubleshooting your redundant system for anomalies with qualification and synchronization check the Synchronization and Synchronization Status tabs of the RMCT Recent Synchronization Attempts The Synchronization tab provides a log of the last four synchronization attempts If a synchronization command was unsuccessful the Recent Synchronization Attempts log indicates a cause For more information about resolving the synchronization conflict click the attempt and view the Description in the lower box Figure 61 Example of an Unsuccessful Synchronization Attempt Recent Synchronization Attempts Order Result N 1 Abort N 3 Success Description Abort Module Pair Incompatible W Module Pair Incompatible N 2 Abort Module Pair Incompatible Refresh Kr 204 One or more modules in the primary chassis has an incompatible partner a Look atthe synchronization status tab to identity which slots are reporting an incompatible partner Check to make sure thatthe primary amp secondary partners are occupying the same slot amp have the same Vendor ID Product Type amp compatible Product Codes Also ensure that the firmware revision of the secondary module is same or greater than its primary partner Additionally for ControlNet communication modules the partners should have the same MAC ID amp keeper signatures amp gt For more inform
41. System Revision 19 052 Enhanced System Revision 19 053 or or later Revision 16 081 later Communicatio 1756 CN2 B ControlLogix ControlNet bridge vA v v v n modules module 1756 CN2R B ControlLogix redundant media v v v v ControlNet bridge module 1756 CN2RXT ControlLogix XT ControlNet bridge v v v v module 1756 EN2T ControlLogix EtherNet IP bridge vA v vA v module 1756 EN2TR ControlLogix EtherNet IP 2 port v v v module 1756 EN2TXT ControlLogix XT EtherNet IP v v v v bridge module 1756 EN2F ControlLogix EtherNet IP 2 port v vA fiber module Controllers 1756 L61 ControlLogix controllers vA v v 1756 L62 1756 L63 1756 L64 1756 L63XT ControlLogix XT controller vA v v 1756 L65 ControlLogix controller v M 1756 L72 ControlLogix controllers vA vA 1756 L73 1756 L74 1756 L75 1756 L71 v 1756 L73XT ControlLogix XT controller vA v Redundancy 1756 RM ControlLogix redundancy module v v v modules 1756 RMXT ControlLogix XT redundancy v v v module 270 Rockwell Automation Publication 1756 UM535D EN P November 2012 Add an Identical Chassis Upgrade to Enhanced Redundancy Firmware Update the Controller Revision and Download the Project Convert from a Nonredundant System Appendix D After you have configured your primary chassis with the modules listed above add an identical chassis that contains the same modules with the same module placement For more information about chassis configura
42. is not in progress 0 Unsupported 1 99 For modules that can measure their completion percentage the percent of synchronization qualification that is complete 50 For modules that cannot measure their completion percentage synchronization qualification is in progress 100 Synchronization qualification is complete Mode switch settings of the Mode switchAlarm DINT GSV If Then controller and its partner match or do i not match 0 e The mode switches match OR e No partner is present 1 Mode switches do not match Position of the mode switchmode Partnermode switch DINT GSV If Then the mode switch is in switch of the partner 0 Unknown 1 RUN 2 PROG 3 REM Status of the minor faults of the PartnerMinorFaults DINT GSV This bit Means this minor fault partner if the ModuleRedundancyState indicates 1 Power up fault that a partner is present 3 10 fault 4 Problem with an instruction program 6 Periodic task overlap watchdog 9 Problem with the serial port 10 Low battery or issue with the energy storage module Mode of the partner PartnerMode DINT GSV If Then 16 0 Power up 16 1 Program 16 2 Run 16 3 Test 16 4 Faulted 16 5 Run to program 16 6 Test to program 16 7 Program to run 16 8 Test to run 16 9 Run to test 16 A Program to test 16 B Into faulted 16 C Faulted to program 274 Rockwell Automation Publication 1756 UM535D EN P November 2012 Redundancy Object Attributes Appendix E For t
43. open the Event Log of the redundancy module that is currently the primary 325919 325918 9 25 2009 10 57 41 6 9 25 2009 10 45 44 9 Event Log Time 5 Module Description Classification 325924 9 25 2009 10 57 41 7 1 9 1756 L63 36 Partner Connection Closed State Changes 325923 9 25 2009 10 57 41 6 3 1756 RM2 18 Chassis Redundancy State changed to PwNS State Changes 325922 9 25 2009 10 57 41 6 2 1756 CN F Partner Connection Closed State Changes 9 25 2009 10 57 41 6 3 1756 RM2 56 The partner RM has been disconnected 325920 9 25 2009 10 57 41 6 3 9 1756 RM2 C Port2 Communication error Minor Fault 3 1756 RM2 C Port2 Communication error Minor Fault 1756 RM 2 sis Redundancy State changed to PwQS Chassis B Event Log Time 5 Module Description Classification 168303 9 25 2009 10 45 44 9 3 1756 RM2 1E Chassis Redundancy State changed to QSwP State Changes 168302 9 25 2009 10 45 44 9 2 9 1756 CN 31 Transition To Qualified Secondary State Changes 168301 9 25 2009 10 45 30 3 2 1756 CN 30 Transition To Qualifying Secondary State Changes 168300 9 25 2009 10 45 25 3 3 1756 RM2 91 Response to Open Bridge Connection Starts Stops 168299 9 25 2009 10 45 25 3 3 1756 RM2 90 Requestto Open Bridge Connection Starts Stops 168298 9 25 2009 10 45 25 3 3 1756 RM2 91 Response to Open Bridge Connection Starts Stops The Event Log clear
44. use a 1756 L64 controller in the same chassis as a 1756 L61 1756 L62 or 1756 L63 controller e You can use different catalog numbers from the same product family in the same chassis For example you can use two 1756 L6x controllers in a chassis e Each controller must have enough data memory to store twice the amount of tag data associated with a redundant controller project Rockwell Automation Publication 1756 UM535D EN P November 2012 29 Chapter2 Design an Enhanced Redundancy System e Each controller must have enough I O memory to store twice the amount of I O memory used To check the I O memory used and available access the Memory tab of the Controller Properties dialog box in RSLogix 5000 software For more information about data and I O memory see Knowledgebase Answer ID 28972 e When you use the redundancy system update RSU feature to update an enhanced redundancy system while the system continues operation the updated secondary controllers must provide the same or greater memory than the primary controllers A secondary controller provides greater memory than the primary controller ifit is a higher catalog number for example a 1756 L63 primary controller and a 1756 L65 secondary controller This table describes the secondary controllers to which you can upgrade based on the primary controller used when using RSU Table 6 Controller Compatibility Primary Controller Compatible S
45. 1 at altitudes up to 2000 m 6562 ft without derating This equipment is not intended for use in residential environments and may not provide adequate protection to radio communication services in such environments This equipment is supplied as open type equipment It must be mounted within an enclosure that is suitably designed for those specific environmental conditions that will be present and appropriately designed to prevent personal injury resulting from accessibility to live parts The enclosure must have suitable flame retardant properties to prevent or minimize the spread of flame complying with a flame spread rating of 5VA or be approved for the application if nonmetallic The interior of the enclosure must be accessible only by the use of a tool Subsequent sections of this publication may contain additional information regarding specific enclosure type ratings that are required to comply with certain product safety certifications In addition to this publication see the following e Industrial Automation Wiring and Grounding Guidelines Rockwell Automation publication 1770 4 1 for additional installation requirements e NEMA Standard 250 and IEC 60529 as applicable for explanations of the degrees of protection provided by enclosure Prevent Electrostatic Discharge ATTENTION This equipment is sensitive to electrostatic discharge which can cause internal damage and affect normal operation Follow these guidelines when you ha
46. 1756 CN2R 1756 CN2R B GJ Backplane 1756 A4 A T 00 1756 L63 LOGIX5563 GDPOD1 Ga 03 1756 RM A E1 4 3 10 1756 CN2R 1756 CN2R E Driver Diagnostics Configure Driver Upload EDS file from device Device Properties Module Statistics 2 Click the Connection Manager tab AB_ETH 1 10 88 22 57 Backplane 0 A 9 Backplane 2 1756 CN2R B Statistics General Port Diagnostics Connection Manager Backplane USB m Statistics Request Format Resourc Other s Rejects Rejects a3 b bb pP e Mp Operi Clos j Connection Timeouts m Connection Statistics Total Connections 131 p gt Connections Used Connection Utilization 131 m Buffer Statistics Max Buffer Size o gt o 0 Size Remaining 0 Buffer Utilization m CPU Statistics gt CPU Utilization 0 100 CPU Utilization Rockwell Automation Publication 1756 UM535D EN P November 2012 197 Chapter 8 198 Monitor and Maintain an Enhanced Redundancy System CPU Usage The CPU usage of the ControlNet modules must be at 80 or less Keeping the CPU usage below 80 reserves enough CPU functionality for the ControlNet module to properly facilitate a switchover If the CPU usage is above 80 the secondary chassis may not be able to synchronize with the primary chassis after a switchover occurs In addition unscheduled communication may be slowed
47. 1756 UM535D EN P November 2012 181 Chapter7 Program the Redundant Controller Online Edits 182 Load a Project If you need to load a project from nonvolatile memory you must first disqualify your redundancy system You then load the project from the primary controller and resynchronize the redundant chassis once the load is complete For details about loading a project from nonvolatile memory see the Logix5000 Controllers Memory Card Programming Manual publication 1756 PM017 You can edit the redundant controller program while the system is online and running However in addition to considerations described in the Logix5000 Controllers Quick Start publication 1756 QS001 considerations specific to redundancy must be made Support for Partial Import Online Beginning with enhanced redundancy system revision 19 052 or later you can use the Partial Import Online PIO feature available in RSLogix 5000 software Consider these points when using PIO with enhanced redundancy systems at revision 19 052 or later e Ifyou select Import Logix Edits as Pending or Accept Program Edits when executing a PIO the primary controller treats the PIO feature as a set of multiple test edits where after the import is complete you can switch between testing the edits or not e We recommend that you do not use Finalize All Edits in Program when importing edits If you use this option any failure due to the import causes a failure on the ne
48. 6 Click Finish The firmware begins to update When the update is complete the Update status dialog box indicates completion p raadas tae arate aa Step 8 Upgrade the Secondary Redundancy Module Firmware and All Other Modules Firmware in the Secondary Chassis Power on the secondary chassis Wait 45 seconds before you begin updating the secondary chassis firmware During this time the redundancy module conducts internal operations to prepare for an upgrade Complete these steps to upgrade the firmware in the secondary chassis 1 Launch ControlFLASH software and click Next 2 Select the redundancy module catalog number and click Next Catalog Number Enter the catalog number of the target device fi 756 RM B Control 1756 08 1615 44 1756 0B32 4 1756 RM ZA 1756 RM B 1756 RM2 A Rockwell Automation Publication 1756 UM535D EN P November 2012 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C 3 Browse to the module and select it Primary Chassis p i J 192 168 1 41 1756 EN2T 1756 EN2T 4 192 168 1 42 1756 EN2T 1756 EN2T 4 amp Backplane 1756 A4 4 00 1756 L73 LOGIXSS73 1756 L73 4 LOGIXSS73 01 1756 RMZ A 1756 RM2 REDUNDANCY MODULE Secondary Chassis _ _ gt 02 1756 EN2T 1756 EN2T 4 4 Click OK 5 Select the firmware revision to upgrade to and click Next 6 Click Finish The firmware begins to update When th
49. 735 1 1756 AM 2 C2 Bridge Connection Deleted Starts 9941 3 24 2012 08 53 44 731 1 1756 AM 2 1D Chassis Redundancy State changed to DSwP State CI 9940 3 24 2012 08 53 44 716 1 1756 AM2 C2 Bridge Connection Deleted Starts 9939 3 24 2012 08 53 44 716 1 1756 AM 2 C2 Bridge Connection Deleted Starts 9938 3424 2012 08 53 44 715 1 1756 AM2 C2 Bridge Connection Deleted Starts 9937 3 24 2012 08 53 44 715 2 1756 EN2T F Partner Connection Closed Synchre 3 24 2012 08 53 44 714 1 1756 AM2 45 SYS_FAIL_L Active Failure 2 es ENT 1 Network Transition to Not Attached Synchre 1 1756AN C 3724 2 2 1756 EN2T Transition To Qualified Secondary State Cl 9429012 NA AA AF 797 175R FN T AM Transition Ta Qialifuina Seeandans ar lt m 207 Chapter9 Troubleshoot a Redundant System 5 Work back in time up the lines of preceding events to locate the point that a switchover or disqualifying event occurred This is the end date and time of the event and will be indicated on the Event line in the A chassis event log with a disqualification code that the secondary has been disqualified and a corresponding disqualification code in the B chassis event log Again note that if no secondary is present you may not see any secondary disqualification codes in the event log at all See Possible Qualification Status Indicators on page 211 Chassis A Module Info Configuration Synchronization Synchronization Status Event Log Sy
50. ATTENTION Class 1 laser product Laser radiation is present when the system is open and interlocks bypassed Only trained and qualified personnel are allowed to install replace or service this equipment Install the Enhanced Redundancy System Chapter 3 A redundant system is comprised of two ControlLogix redundancy modules working together that supervise the operating states and state transitions that establish the basic framework for redundancy operations The redundant pairs provide a bridge between chassis pairs that let other modules exchange control data and synchronize their operations This illustration identifies the external features of the module Figure 12 1756 RM2 A or 1756 RM2XT Modules 1756 RM2 A Module Top View 1756 RM2XT Module Top View Front View Front View Status Indicators Status Indicators Side View Side View y CH2 CH1 HE 7 Backplane Bottom View Connector Bottom View 32269 M 46057 NOTE SFP transceivers are pre installed in the redundant fiber ports Rockwell Automation Publication 1756 UM535D EN P November 2012 61 Chapter3 Install the Enhanced Redundancy System Figure 13 1756 RM A or RM B and 1756 RMXT Modules
51. Changes 747430 11 16 2010 14 12 54 895 7 1756 AM 91 Response to Open Bridge Connection Starts Stops 747429 11 16 2010 14 12 54 895 7 1756 RM 90 Request to Open Bridge Connection Starts Stops 747428 11 16 2010 14 12 54 886 7 1756 RM 91 Response to Open Bridge Connection Starts Stops 747427 11 16 2010 14 12 54 885 7 1756 RM 90 Request to Open Bridge Connection Starts Stops 747426 11 16 2010 14 12 54 882 1 1756 CN2R 33 Partner Ping Successful Configuration 747425 11 16 2010 14 12 54 8576 1 1756 CN2R 10 Partner Connection Opened State Changes 7 7 7 7 Export Diagnostics Clear Fault Extended Info gt gt Chassis A Primary with Disqualified Secondary z Auto Synchronization State Never Chassis Platform Configuration Enhanced Epply Help Rockwell Automation Publication 1756 UM535D EN P November 2012 Event Classifications 121 Chapter 6 Configure the Redundancy Modules Use this table to determine what an event classification indicates and if corrective action is required Table 21 Classification Types Classification Type Description Action Required Configuration Aredundancy module configuration parameter has been changed No corrective action is required For example if you change the Auto Synchronization parameter from This event is provided for informational purposes and does not indicate Always to Never an event classified as Configuration is logged seriou
52. Codes and Display Messages Recovery Messages Appendix B Event Log Descriptions Appendix C Upgrade from a Standard Redundancy System Before You Begin Upgrade System Components Upgrade the System Software Upgrade the Controllers Replace Communication Modules Steps After System Components Upgrade Upgrade Ethernet Modules When Rotary Switches Are Set Dig fd eS A ee ee ee eo ee Upgrade by Using Redundancy System Update Replace 1756 RM A or 1756 RM B Redundancy Modules with 1756 RM2 A Redundancy Modules Appendix D Update the Configuration in RSLogix 5000 Software Replace Local I O Tags Replace Aliases to Local I O Tags is tabetie ental tevin ce wees uetens Remove Other Modules from the Controller Chassis Add an Identical Chassis Upgrade to Enhanced Redundancy Firmware 00 0005 Update the Controller Revision and Download the Project Appendix E Redundancy Object Attributes Appendix F Chassis Configuration Checklist Remote I O Checklist Redundancy Module Checklist ControlLogix Controller Checklist ControliNet Ch ellistics ised anaee amine sb tacostna wet wan does EtherNet IP Module Checklist Project and Programming Checklist o vcoucday sean eenewees Rockwell Automation Publication 1756 UM535D EN P November 2012 Table of Contents Appendix G Enhanced Redundancy Revision Changes to This Matiual cc onteiyosins i tives mem ated hte 283 History Index Rockwell Automation Publicat
53. Compatible NUTs are determined based on the network that uses the smallest NUT 95 Chapter5 Configure the ControlNet Network Use this table to determine the compatible NUTs for your system Table 15 Compatible NUT Values for Multiple ControlNet Networks If the smallest NUT of a Then the largest NUT of any other network must be less network is ms than or equal to ms 2 15 3 17 4 19 5 21 6 23 7 25 8 27 9 29 10 31 11 33 12 35 13 37 14 39 15 4 16 43 17 46 18 48 19 50 20 52 21 55 22 57 23 59 24 62 25 64 26 66 27 68 28 71 29 73 30 75 31 78 32 80 33 82 34 84 35 87 36 89 37 90 90 96 Rockwell Automation Publication 1756 UM535D EN P November 2012 Use a Scheduled or Unscheduled Network Configure the ControlNet Network Chapter 5 It is up to the user to decided between using a scheduled or unscheduled network Use a Scheduled Network Schedule or reschedule your ControlNet network when you are executing these tasks e Commissioning a new redundant system e Adding a new chassis of remote ControlLogix I O that is set to use the Rack Optimized communication format e Adding any remote I O besides ControlLogix I O For example if adding FLEX I O modules you must schedule the network e Using produced consumed data Any time you add a produced consumed data tag you must reschedule the
54. Conditional or Never before disqualifying the secondary Initiate Switchover This command forces the system to initiate an immediate switchover from the primary chassis to the secondary chassis This command can be used when upgrading redundancy system firmware or when completing maintenance on one chassis of the redundant pair This command can also be used to perform a realistic test of your redundant system behavior by simulating a failure detected in the primary control chassis This command is available in specific conditions Available only when the chassis redundancy state is as follows Primary with Synchronized Secondary Synchronized Secondary e Unavailable dimmed in all other chassis states Become Primary This command forces a disqualified secondary system to become a primary system and is available in specific conditions Available only when the chassis redundancy state is Secondary with No Primary e Unavailable dimmed in all other chassis states Rockwell Automation Publication 1756 UM535D EN P November 2012 117 Chapter 6 Configure the Redundancy Modules Recent Synchronization Attempts Log This table describes the possible result and causes of synchronization states Table 18 Recent Synchronization Attempts Log Result Interpretations Result Result Interpretation Undefined The result of the synchronization is unknown No attempt since last powerup Synchronization has not
55. ControlNet modules with a Logix5000 controller EtherNet IP Modules in Logix5000 Control Systems publication ENET UMO001 Describes how to use EtherNet IP communication modules with your Logix5000 controller and communicate with various devices on the Ethernet network Ethernet Design Considerations for Control System Networks publication ENET S0001 Provides fundamental best practice guidelines for designing the Ethernet infrastructure for your Supervisory Controls and Data Acquisition SCADA and MES Manufacturing Execution Systems systems with Rockwell Automation software and hardware products EtherNet IP Embedded Switch Technology Application Guide publication ENET AP005 Describes how to configure and implement a device level ring topology EtherNet IP Socket Interface Application Technique publication ENET AT002 Describes the socket interface used to program MSG instructions to communicate between a Logix5000 controller via an EtherNet IP module and Ethernet devices that do not support the EtherNet IP application protocol such as bar code scanners RFID readers or other standard Ethernet devices You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Allen Bradley distributor or Rockwell Automation sales representative 14 Rockwell Automation Publication 1756 UM535D EN P November 2012 Chapter
56. Data Types Grouped aa z Dint_2 DINT Description Bool_3 BOOL Bool_1 Bool_2 BOOL Decimal Bool_3 BOOL Decimal Dint_1 DINT Decimal Dint_2 DINT Decimal Group Data into Arrays of User Defined Data Types by Frequency of Use 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 contains 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 frequently your program uses it Rockwell Automation Publication 1756 UM535D EN P November 2012 155 Chapter 7 156 Program the Redundant Controller Figure 43 Tags Grouped into User Defined Data Types by Frequency of Use Tag Name My_Bools For example if your application uses DINTs that you use only as constants to initialize your logic BOOLs that you update every scan and REALs that you update every second you can create a separate User Defined Data Type for each type of tag that is used at different points in the application Using separate User Defined Data Types for each group rather than grouping all of the tags together in one User Defined Data Type helps to minimize the amount of data transferred during the cr
57. History Initiation Time Status Result N 6 2 2009 22 45 07 175 Locked System locked at 6 2 2009 22 45 38 849 N 1 Not atternpted Not attempted Not attempted 5 Click Initiate Locked Switchover then click Yes Initiate Locked Switchover This step results in your secondary chassis assuming control and becoming the primary chassis When the switchover is complete the Locked Switchover Attempts log indicates success Locked Switchover Attempts Locked Switchover History Initiation Time Status Result N 6 2 2009 22 47 21 032 Success Locked switchover completed at 6 2 2009 22 47 21 035 N 1 Not attempted N 2 Not attempted N 3 Not attempted In addition to the log the text in chassis status row indicates the switchover state Chassis B Primary with Disqualified Secondary Auto Synchronization State Never Once your locked switchover is complete upgrade the firmware revisions for modules in the new secondary chassis IMPORTANT Following the locked switchover secondary controllers no longer contain a user application and their configuration settings are reset to the factory default settings The new secondary controllers use the default settings and the components in the secondary chassis are upgraded and the system is synchronized Step 11 Upgrade the New Secondary Chassis Firmware Complete these steps to upgrade the firmware of all of the modules in t
58. NO Unconfigured To correct this anomaly do one of the following e Select the unconfigured module and click Update Keeper e Reschedule the ControlNet network 218 Rockwell Automation Publication 1756 UM535D EN P November 2012 ControlNet modules in the redundant chassis with different keeper signatures Keeper Signature Mismatch Troubleshoot a Redundant System Chapter 9 This example shows ControlNet modules in the redundant chassis that do not have the same keeper signatures With this anomaly the ControlNet module display indicates Keeper Signature Mismatch This anomaly may result if a ControlNet module configured for the same node of another network is used to replace a ControlNet module with the same node address in the redundant chassis Figure 64 Keeper Status Signature Mismatch 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 ies per Offline File 01 YE S ToP re 06 NO Ds4a a4ced OF NO Oxda8adced 09 NO Oxda8adced 10 NO Oxf3fd3d66 To correct this anomaly do one of the following e Select the unconfigured module and click Update Keeper e Reschedule the ControlNet network Rockwell Automation Publication 1756 UM535D EN P November 2012 219 Chapter 9 Tr
59. NSONL_Example Driver Diagnostics 02 1756 EN2T 1756 EN2T amp Configure Driver 03 1756 RM2 A 1756 RM2 REDUNDANCY Mop _ Upload EDS file From device Security Device Properties Rockwell Automation Publication 1756 UM535D EN P November 2012 109 Chapter 6 110 Configure the Redundancy Modules The Module Configuration dialog box opens 4 Right click the title bar and choose About Module Info Configuration Synchronization Synchronization Status Event Log Syst Move Redundancy Module Identification Status G Wee Minimize Vendor Rockwell Automation Allen htt m Bradley Major Fault Product Type Redundancy Product Minor Fault Close Alt F4 Error Code The About dialog box opens and indicates the RMCT version About Redundancy Configuration Tool Ta Redundancy Configuration Tool Version 8 1 2 0 Copyright c 2011 Rockwell Automation Technologies Inc All Rights Reserved Update the RMCT Version The RMCT version that is compatible with your redundancy module firmware is packaged with the redundancy system firmware bundle To launch the installation of the RMCT open the folder that contains the redundancy firmware revision and double click the executable file titled Redundancy_Module_CT exe The RMCT Installation Wizard opens and prompts you with the steps required to install the RMCT Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Re
60. Network Transition t Not Attached Synchre L 9934 1 1756 RM2 1E Chassis Redundancy State changed svi State Cl Start 9933 2 1756 EN2T 31 Transition To Qualified Secondary State Cl 9937 2 APAR FN T IAN Transitinn Ta Qualifiinn Serandan State PIY lt i F2 l l l l l l l Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History Auto Update Chassis B Event Log Time Slot Module Na Description Classific A 2 9945 3 24 2012 08 53 44 795 1 1756 RM 2 C2 Bridge Connection Deleted Starts 9944 3 24 2012 08 53 44 775 1 1756 RM 2 C2 Bridge Connection Deleted Starts End 9943 SNA 2 Wss a 755 1 1756 RM 2 C2 Bridge Connection Deleted Starts 9942 3 24 gt 1 1756 RM 2 C2 Bridge Connection Deleted Starts 941 qian 2 E 53 a 731 1 1756 RM 2 1D Chassis Redundancy State changed sve State Cl 9940 3 24 1 1756 RM 2 C2 Bridge Connection Deleted Starts l 9939 37247201 2 08 53 44 716 1 1756 AM2 C2 Bridge Connection Deleted Starts We es eee a oe 9938 3 24 2012 08 53 44 715 1 1756 AM 2 C2 Bridge Connection Deleted Starts 9937 3 24 2012 08 53 44 715 2 1756 EN2T F Partner Connection Closed Synchre 9936 3 24 2012 08 53 44 714 1 ees AM 12 15 SYS_FAIL_L Active Faire 9935 4 2012 NAR 44 713 Error 2934 1 175GRM2 IE Chassis Redundancy State changed asw State Cl Start 9933 2 1756 EN2T 31 Transition To Qualified Secondary Stat
61. November 2012 23 Chapter2 Design an Enhanced Redundancy System Com ponents of an Enhanced The central components of a ControlLogix enhanced redundancy system are Redundancy System those in the redundant chassis pair You can connect other system components to the redundant chassis pair However the redundant chassis pair and the components within it provide redundant communication and control features This table lists the components available with enhanced redundancy systems Please note that some component availability is revision specific Table 4 Components Available for Use in a Redundant Chassis Pair Product Type Cat No Description Page Redundancy 1756 RM2 A ControlLogix redundancy module module This component is available with enhanced redundancy systems revision 16 057 16 081 19 052 or later when using 1756 L6x controllers and 19 053 or later when using 1756 L7x controllers 1756 RM2XT ControlLogix XT redundancy module This component is available with enhanced redundancy 31 systems revision 16 057 16 081 19 052 or later when using 1756 L6x controllers and 19 053 or later when using 1756 L7x controllers 1756 RM ControlLogix redundancy module 1756 RMXT ControlLogix XT redundancy module Chassis 1756 A4 ControlLogix 4 slot chassis 1756 A4LXT ControlLogix XT 4 slot chassis 25 60 C 13 140 F This component is available with enhanced redunda
62. Path Redundant_ENET Redundant_ENET Communication Method CP C DH Channe Destination Link C CIP With Source Link fo Destination Node Source ID Connected Jv Cache Connections e Rockwell Automation Publication 1756 UM535D EN P November 2012 171 Chapter 7 172 Program the Redundant Controller Configure the MSG Instruction Use the MSG configuration settings that correspond to the command you intend to issue to the redundancy modules If you need to Initiate a Switchover See page 172 Disqualify the Secondary Chassis 174 Synchronize the Secondary Chassis 174 Set the Redundancy Module Date and Time Initiate a Switchover 175 To initiate a switchover use the MSG instruction parameters listed in this table Table 29 MSG Instruction to Initiate a Switchover In this tab Edit this element To use this value Configuration Message Type CIP Generic Service Type Custom Service Code 4e Class bf Instance 1 Attribute None no value needed Source Element INT tag with a value of 1 Source Length 2 Destination Element None no value needed Communication Path Browse for the path to the 1756 RM or 1756 RMXT redundancy module Connected box Leave the Connected checkbox unchecked Rockwell Automation Publication 1756 UM535D EN P November 2012 Program the Redundant Controller Chapter 7 Use this table to when using MS
63. Product Minor Fault Error Code Product Code 3 n Error Message Revision 20 4 4 Recovery Message Fiber Channel Switchover Counters Serial Number 00856DA6 Total 8 Product Name 1756 RM2 REDUNDANCY Periodic 0 RLE Max Periodic 0 User Defined Identity Name Description Location Chassis A Primary with Synchronized Secondary CH1 Status Active CH2 Status Redundant Futo Synchronization State Aways Chassis Platform Configuration Enhanced OK ee Help Rockwell Automation Publication 1756 UM535D EN P November 2012 129 Chapter6 Configure the Redundancy Modules System Update Tab Use of the commands in the System Update tab lets you perform firmware updates in the secondary chassis while the primary chassis remains in control Reference the lock and switchover logs in this tab for update information when completing a firmware update in the System Update tab redundancy is lost In the event of a fault on the operating primary chassis the system cannot switch control to the secondary chassis i ATTENTION When performing firmware updates by using commands Module Info Configuration Synchronization Synchronization Status EventLog System Update System Event History m System Update Commands Lock For Update Abort system Lock Initiate Locked Switchover m System Update Lock Attempts System Lock History Initiation Time Status Result N Not attempted N 1 Not atte
64. RM2 1756 RM A REDUNDANCY MODULE y 10 1756 CN2R 1756 CN2P B Backplane 1756 A4 A 01 1756 L73 LOGIX5563 GDPOD1_ALARMS i 02 1756 CN2R 1756 CN2R B 03 1756 RM2 Chassis B To correct the missing module anomaly first verify that the redundancy module is correctly installed in the chassis and it is properly powered Then check the intermodule cable that connects the redundancy modules After you have verified that the module is installed and powered you may need to synchronize the chassis by using the synchronization commands in the Synchronization tab Use the synchronization commands if your Auto Synchronization parameter for the chassis is not set to Always Rockwell Automation Publication 1756 UM535D EN P November 2012 Troubleshoot a Redundant System Chapter 9 Qualification Aborted Due to r you place a ee se is enabled hierniana into redundant chassis the qualification and synchronization fail Io determine if your a Nonredundant Controller synchronization failure is due to a nonredundant controller complete these steps 1 Ifnot already open open the RMCT of the primary module 2 Click the Synchronization tab and view the Recent Synchronization Status Attempts log The log indicates there is a Module Configuration Error 3 Select the aborted attempt to view the description Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History
65. Redundant Chassis Pair HMI Connected via i g 3 1783 ETAP Taps Physical connection is not made yet Remote ControlLogix Chassis with Redundant Power 1715 Redundant 1 0 System Supplies and 1 0 Modules Rockwell Automation Publication 1756 UM535D EN P November 2012 91 Chapter4 Configure the EtherNet IP Network 2 Configure and enable one active supervisor and any back up nodes on the network Use either of these tools to configure and enable supervisor nodes on a DLR network e RSLogix 5000 programming software e RSLinx Classic communication software 3 Complete the physical connections on the network to establish a complete and fully functioning DLR network This figure shows the example DLR network on page 91 with all physical connections complete Figure 26 Fully Connected DLR Network E gt FactoryTalk Application Eon iS TTIE Cisco Switch EH iE stratix 8000 Switche it ape Stratix witches Redundant Chassis Pair HMI Connected via 5 Physical 1783 ETAP Taps H a 2 connection is made oo AL ELELEE S He on T Remote ControlLogix Chassis with Redundant Power 1715 Redundant 0 System Supplies and 1 0 Modules 4 Verify supervisor configuration and overall DLR network status with either of these tools e RSLogix 5000 software e RSLinx Classic communication software 92 Rockwell Automation Publication 1756 UM535D EN P November 2012 Chapter 5 Configure th
66. Rockwell Automation Publication 1756 UM535D EN P November 2012 237 AppendixB Event Log Descriptions Event Description Modules chassis state rule Description 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 Partner not on same link A primary communication module cannot communicate with its partner across the network For example a 1756 CN2R B communication module in the primary chassis cannot communication with its partner 1756 CN2R B communication module in the secondary chassis These conditions may result in this event e A network anomaly such as noise a poor connection or a termination anomaly exists The secondary communication module is not connected to the same network as the primary or any network at all 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 Primary
67. Use this setting to change crossload and synchronization points Crossloading and synchronization points are points where the primary controller transfers data to the secondary controller Crossload and synchronization points keep the secondary controller ready to assume control in the event of a fault on the primary Before you begin programming your redundant controller be aware of the impact of crossloads and synchronization on the execution of a program after a switchover Understanding these concepts helps you to create programming that best meets the needs for your redundant application Continue reading the sections that follow for explanations of crossloads and synchronization and their relationship to switchovers and program execution Changing Crossload and Synchronization Settings In the enhanced redundancy system crossload and synchronization points for programs within the RSLogix 5000 project are configurable You can limit which programs are followed by data crossloading and synchronization In many applications changing this setting can reduce the overall impact to the task scan time by reducing the number of times data is crossloaded Ifyou reduce the number of crossload and synchronization points the switchover time becomes longer This increase in switchover time is because more programs may be rescanned after the switchover Synchronization is performed at the end of the last program in the task s program list regar
68. be enforced by the module itself The compatibility status Compatible or Incompatible is determined by either the module in the primary chassis or its partner in the secondary chassis The redundancy module pair must occupy the same slots in their respective chassis The redundancy module pair does not consider the chassis pair to be partnered if the redundancy modules are placed in different slots even if the partners of other modules are present in the same slot 54 Rockwell Automation Publication 1756 UM535D EN P November 2012 Install the Enhanced Redundancy System Chapter 3 The redundancy module prevents certain redundancy operations such as Qualification if incompatible modules reside in the redundant control chassis pair IMPORTANT For best performance place the redundancy module in the chassis as close as possible to the controller Complete these tasks to install the first chassis in the redundant chassis pair e Install the Chassis and Power Supply e Install the Communication Modules e Install a Controller e Install the Redundancy Module TIP Do not apply power to the system until both chassis and their components are installed Then follow the steps described in Step 4 Update Redundant Chassis Firmware on page 67 to determine when to power each chassis Install the Chassis and Power Supply Use the installation information provided with the chassis and power supply or redundant power supplies
69. became PTP time synchronized The primary module is now PTP synchronized and an auto qualification was requested Program Fault A controller has a major fault PTP not synchronized A redundant controller s PTP clock is not synchronized or the partner controller pair is synchronized to different grandmasters PTP now synchronized PTP is now synchronized on the module 1756 RM OS error The redundancy module has an anomaly 1756 RM 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 1756 RM 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 Because 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 an anomaly The signal is normally false inactive which means that all modules in the chassis are OK 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 t
70. been attempted since power was applied to the module Success Full synchronization was successfully completed Abort The synchronization attempt failed See the table Recent Synchronization Attempts Log Result Interpretations for further information If the Synchronization Attempts log indicates that the Synchronization attempt was aborted use this table to further interpret the cause Table 19 Synchronization Interpretation Cause Undefined Cause Interpretation The cause of synchronization failure is unknown Module Pair Incompatible Synchronization aborted because one or more module pairs are incompatible Module Configuration Error Synchronization aborted because one of the modules is improperly configured Edit Session In Progress Synchronization aborted because an edit or session is in progress Crossloading Failure An undetermined failure occurred during synchronization between redundancy modules Comm Disconnected The cable between the redundancy modules was disconnected Module Insertion Synchronization aborted because a module was inserted into a chassis Module Removal Synchronization aborted because a module was removed from a chassis Secondary Module Failed Synchronization aborted because of a failure in the secondary module Incorrect Chassis State Synchronization aborted due to an incorrect chassis state Comm Does Not Exist Synchron
71. chassis has asserted the SYS_FAIL line indicating that it has faulted or failed Auto Sync Option 118 Synchronization was aborted because the Auto Synchronization parameter of one of the redundancy modules was changed during synchronization Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Redundancy Modules Chapter 6 Table 19 Synchronization Interpretation Cause Module Qual Request Cause Interpretation Synchronization was aborted because another synchronization request was received The current synchronization has stopped so that the new synchronization request can be serviced SYS_FAIL_L Deasserted Synchronization was aborted because one of the modules came out of a faulted or failed state Disqualify Command Synchronization was aborted because the redundancy module received a disqualify command from another device The originating device sends this command when it is no longer capable of performing in the qualified state Disqualify Request Synchronization was aborted because the redundancy module received a disqualify command from another device The originating device sends this command when it is no longer capable of performing in the qualified state Platform Configuration Identity Mismatch Detected There are modules in the primary or secondary chassis that do not belong to the enhanced platform Application Requires Enhanced Platform A redundant cont
72. controller Then During the erroring out of a message All backplane communication ceases This stoppage allows the redundant controller to receive the message instruction required to perform a switchover or any diagnostics Important If any of your messages are active during a switchover you can expect one of these things to happen e Cached and connected messages cause the message instruction to pause for 7 5 seconds because the initiating controller has not received a response from the targeted controller For cached messages the message instruction tries to execute three more times each attempt followed by a pause of 7 5 seconds If after 30 seconds pass the targeted controller does not respond to the initiating controller then the switchover errors out with connected time out Error 1 Extended Error 203 An example of a connected message would be CIP data table read and write messages after a connection has been established Uncached messages error out after 30 seconds if you have just initiated them because the initiating controller never received a reply to the forward open request The error is Error 1F Extended Error 204 an unconnected time out Examples of uncached messages would include CIP generic messages and messages captured during the connection process During qualification Cached messages run with no errors A connection has been established Connected but uncached messages or unconnected messages e
73. date and start time in Chassis A This is the last time the redundancy module was working properly j Chassis B QSwP and start date and start time in Chassis B This is the last time the redundancy module was working properly and by time must match up with Chassis A gt Rockwell Automation Publication 1756 UM535D EN P November 2012 Troubleshoot a Redundant System Chapter 9 2 Ifan event occurred open the Event Log for both chassis A and B 3 Locate the Event line that shows the qualification code start date and time of the event in the A chassis event log This is the last time the redundancy module was working properly Please note multiple codes could be displayed if multiple errors occurred Additionally ifa secondary redundancy module is not present then a code may not be seen at all See Possible Qualification Status Indicators on page 211 Then locate the matching time entry in the B chassis event log This will display the disqualification code on the Event line 4 Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History Auto Update m Partner Log CON OFF C OPEN CLOSE Export Selection Export All Chassis A Event Log Time Slot Module Na Description Classific 10375 3 24 2012 08 53 44 7350 1756 L73 36 Partner Connection Closed State C 10374 3424 2012 08 53 44 735 1 1756 AM2 C2 Bridge Connecti
74. descriptions for the 1756 RM A and 1756 RM B 231 modules Replace 1756 RM B redundancy modules with 1756 RM2 A redundancy modules 264 without initiating a switchover Rockwell Automation Publication 1756 UM535D EN P November 2012 Preface About Enhanced Redundancy Systems Design an Enhanced Redundancy System Install the Enhanced Redundancy System Table of Contents Additional Resources 0 cc cece ce eee cece cece eeeeceeennaeees Chapter 1 Features of the ControlLogix Enhanced Redundancy System Enhanced Redundancy System Components 00 esse eee I O Modules in Enhanced Redundancy Systems Enhanced Redundancy System Operations se eee e ee System Qualification and Synchronization s s eseese SWIECHOVEIS Tran Uda sua tun Agia of Vota tte Ue I ook cue RestrictiGn ss esc stectaecanien tees ea aS A Sea en bee hae Chapter 2 Components of an Enhanced Redundancy System 0 5 Redundant Chassis e ea aa acid be E E tenet Controllers in Redundant Chassis 0 2 eee ee eee e ees Redundancy Modules in Redundant Chassis 00204 Communication Modules in Redundant Chassis Power Supplies and Redundant Power Supplies in Enhanced Redundancy Systems 2s0 deet ic antago vary eieeehindalaus EDES EtherNet IP Networks with Redundant Systems 0 665 EtherNet IP Network Features in an Enhanced Redundancy System
75. e A module declined a locked switchover readiness request e An invalid response was received from the locked switchover readiness request e After an initiate switchover prompt a module rejected the command e After an initiate switchover prompt a module replied with an invalid response Rockwell Automation Publication 1756 UM535D EN P November 2012 135 Chapter6 Configure the Redundancy Modules System Event History The System Event History tab provides a log of the last 10 major system events The events logged here provide information specific to qualification disqualification switchovers and redundancy module faults For each event logged this information is provided Time and date of the event Event class for example Qualification or Disqualification Basic info about the origin of the event for example Commanded or Auto Qualification Extended information about the event An editable user comment Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History m Event History Sint ta an aa Description 136 EN EEE 12 22 7 24 2009 12 22 7 24 2009 12 15 7 24 2009 12 14 7 24 2009 12 14 7 24 2009 12 14 7 24 2009 12 14 7 24 2009 12 12 Final attempt to test system Event Class Extended Info Extended Info B Qualification Qualification Dis Qualification Qualification Qualification Qualification Dis
76. execute by using incorrect data Table 25 Scan dependent Logic Interrupt by higher Switchover priority task A Counter instruction is used to count each scan of the program TU scan_count c Count Up cu Counter scan_count Preset 1000 DN gt Accum 0 An Equal To instruction uses the accumulated scan_count value as a reference to turn on an indicator when the thousandth scan is complete QU Scan_Count_Light Equal Source amp scan_count A4cc 0 1000 Source B Rockwell Automation Publication 1756 UM535D EN P November 2012 161 Chapter7 Program the Redundant Controller Bind Dependent Instructions with UID and UIE Instructions If you cannot place scan dependent instructions in the highest priority task consider using the User Interrupt Disable UID and User Interrupt Enable UIE to prevent a higher priority task from interrupting the scan dependent logic For example if you bind the scan dependent logic previously shown a higher priority task would not interrupt the dependent instructions and a switchover would not result in inconsistent data Figure 47 Scan dependent Instructions Bound with UID and UIE Instructions UID A Counter instruction is used to count each scan of the program TU scan_count cU cU3 U DN3 Count Up Counter scan_count Preset 4000 Accum 0 UID and UIE keep higher priority tasks from interrupting the logic
77. fiber cables In addition you can click Change to edit the User Defined Identity parameters to meet your application needs Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Redundancy Modules Chapter 6 Configu ration Tab Use the Configuration tab to set redundancy options and the module s internal clock After you modify a parameter the Apply Workstation Time button becomes active Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History f Redundancy Module Options Auto Synchronization Always Serial Number 00856D46 Name Chassis ID Description V Enable User Program Control locations r Redundancy Module Date and Time Current Date 10 3 2012 Current Time 1 53 50 PM Set Date Format C dd mm ppyy mmdd yyyy Apply Workstation Time Chassis B Primary with Synchronized Secondary CH1 Status Active CH2 Status Redundant Futo Synchronization State Aways Chassis Platform Configuration Enhanced OK Apply Help Rockwell Automation Publication 1756 UM535D EN P November 2012 113 Chapter6 Configure the Redundancy Modules Auto Synchronization The first parameter in the Configuration tab is the Auto Synchronization parameter The value you set this parameter to determines a significant part of your redundant system behavior TIP Verify that your Auto Synchronization para
78. information see Use at Least Four ControlNet Network Nodes on page 38 through Assign Lowest Node Numbers to Remote ControlNet Modules on page 39 e You cannot use Series A ControlNet communication modules in a redundancy system e The Series for EtherNet IP communication modules is not required to match in a partnered set However if your application requires a feature specific to a module series level you must use the same series level for each module in a partnered set For example only the 1756 EN2T C communication module only offers the double data rate DDR feature You must use 1756 EN2T C modules in each chassis of the redundant chassis pair to use DDR e Do not use the USB ports of communication modules to access the redundant system network while the system is running that is online Using the USB ports while online can result in a loss of communication after a switchover For a list of the ControlLogix communication modules available for use in an enhanced redundancy system see Table 4 on page 24 32 Rockwell Automation Publication 1756 UM535D EN P November 2012 Design an Enhanced Redundancy System Chapter 2 Plan for Communication Module Connections A CIP connection is a point to point communication mechanism used to transfer data between a producer and a consumer These are examples of CIP connections e Logix5000 controller message transfer to Logix5000 controller e I O or produced tag e Progra
79. inspection par les autorit s locales qualifi es au moment de l installation A 60 a AVERTISSEMENT EXPLOSION HAZARD Do not disconnect equipment unless power has been removed or the area is known to be nonhazardous Do not disconnect connections to this equipment unless power has been removed or the area is known to be nonhazardous Secure any external connections that mate to this equipment by using screws sliding latches threaded connectors or other means provided with this product Substitution of components may impair suitability for Class Division 2 If this product contains batteries they must only be changed in an area known to be nonhazardous A Laser Radiation Ports Rockwell Automation Publication 1756 UM535D EN P November 2012 AVERTISSEMENT RISQUE D EXPLOSION e Couper le courant ou s assurer que l environnement est class non dangereux avant de d brancher l quipement e Couper le courant ou s assurer que l environnement est class non dangereux avant de d brancher les connecteurs Fixer tous les connecteurs externes reli s cet quipement l aide de vis loquets coulissants connecteurs filet s ou autres moyens fournis avec ce produit e La substitution de composants peut rendre cet quipement inadapt une utilisation en environnement de Classe Division 2 e S assurer que l environnement est class non dangereux avant de changer les piles
80. into the remaining port 5 The first end of the fiber cable should plug into the CH1 port on the first chassis and the matching end should plug into the matching CH1 port on the second chassis 46059 Rockwell Automation Publication 1756 UM535D EN P November 2012 65 Chapter3 Install the Enhanced Redundancy System Connect the Fiber optic Communication Cable to Single Channels Follow this procedure to install the communication cable IMPORTANT The redundancy module communication cable contains optical fibers Avoid making sharp bends in the cable Install the cable in a location where it will not be cut run over abraded or otherwise damaged 1 Remove the black protective plug on the first redundancy module in the redundant chassis pair 2 Remove the protective caps from the cable 3 Plug the cable connector into the first redundancy module 4 Plug the remaining cable connector end to the second redundancy module D 0 lt lt x EN SN AN EN A EN NS SEn PIONS Ay NEA Be EAN ENA 44493
81. module lost connection 222 missing 223 RMCT 206 synchronization keeper status 216 use RSLogix 5000 software 201 RSNetWorx for ControlNet software 217 U unicast communication module 22 produced tags 85 remote controller 84 Universal Remote 1 0 43 unscheduled ControlNet network 97 unsupported feature motion 17 SIL3 17 update RMCT 110 system commands 131 133 update firmware 52 Rockwell Automation Publication 1756 UM535D EN P November 2012 upgrade components 240 firmware 67 71 Redundancy Module Configuration Tool 252 software 251 user comment 137 user program control 115 utilities BOOTP DHCP 86 Index V version RMCT 109 Ww watchdog time 177 281 workstation software 51 Rockwell Automation Publication 1756 UM535D EN P November 2012 293 Index Notes 294 Rockwell Automation Publication 1756 UM535D EN P November 2012 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools You can also visit our Knowledgebase at http www rockwellautomation com knowledgebase for FAQs technical information support chat and forums software updates and to sign up for product notification u
82. 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 WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures gt eee IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley ControlFLASH ControlLogix FactoryTalk PanelView PhaseManager Rockwell Software Rockwell Automation RSLinx RSLogix RSNetWorx VersaView RSView32 Logix5000 ControlLogix XT Integrated Architecture Stratix 8000 PowerFlex POINT I O are trademarks of Rockwell Automation Inc Trademarks not belonging
83. power Solid red One of these conditions exists The redundancy module is conducting a self test during powerup No action necessary e The redundancy module has experienced a major fault Cycle power to clear the fault If the major fault does not clear replace the module Flashing red One of these conditions exists e The redundancy module is updating its firmware No action necessary e The redundancy module has been configured improperly Check the module configuration and correct any issues e The redundancy module has experienced a minor failure Cycle power to clear the fault If the major fault does not clear replace the module Solid green The redundancy module is operating normally No action required Flashing green The redundancy module is operating normally but is not communicating with the other redundancy module If necessary establish communication with the other redundancy module Communication Status Indicator The communication status indicator indicates activity on the redundancy module communication between chassis in the redundant chassis pair Table 45 Communication Status Indicator Indicator State Off Description One of these conditions exist e No power is currently applied to the module Apply power to the module There is no communication between redundancy modules in the redundant chassis pair Diagnose the redundancy configuration to determine why
84. preconditions try to group instructions that can be preconditioned by the same instructions together In this example the four preconditions used in the two branches can be combined to precede the two branches Doing so reduces the number of precondition instructions from four to two Figure 45 Efficient Precondition Use MSG Type CIP Data Table Write Message Control MSG_1 J 17 MSG Type CIP Data Table Write Message Control MSG_2 17 Bool_A Bool_B Bool_D MSG Type CIP Data Table Write Message Control MSG_1 ij 17 Bool_C Bool_E MSG Type CIP Data Table Write Message Control MSG_2 ij 17 Rockwell Automation Publication 1756 UM535D EN P November 2012 Program to Maintain Data Integrity Program the Redundant Controller Chapter 7 When programming your redundant controllers there are some instructions and techniques that may cause data loss or corruption when used These instructions and techniques include the following e Array File Shift Instructions e Scan dependent Logic Array File Shift Instructions Interruptions to Array File Shift Instructions by an a higher priority task and then switchover can result in an incomplete data shift and corrupted data These Array File Shift instructions may result in corrupt data in the event of a switchover e Bit Shift Left BSL e Bit Shift Right BSR e FIFO Unload FFU If Array File
85. serious anomaly with the redundancy system Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Redundancy Modules Chapter 6 Access Extended Information About an Event Events logged in the Event Log tab can have additional information available To access additional information about an event double click an event listed in the log Chassis B Event Log Time Slot Module Na Description Classification 143 10 2 2012 15 27 41 541 3 1756 RM 14 Chassis Redundancy State changed State Changes 142 10 2 2012 15 27 41 411 2 1756 EN2T 14 Enter Qualification Phase 4 Qualification 10 2 2012 15 27 41 381 3 1756 AM _ 2E Qualification Complete Qualification 140 10 2 2012 15 27 41 379 2 1756 EN2T 13 Enter Qualification Phase 3 Qualification 139 10 2 2012 15 27 40 381 2 1756 EN2T 12 Enter Qualification Phase 2 Qualification Double click to open extended information Extended Information Definition Chassis B Event Information Scroll to view details Event Number 141 Log Time 10 2 2012 15 27 41 381 of other events Event Class Qualification Submitter Information Module Type 1756 RM Slot No Serial No in Hex 856DA6 View the Description Event Details and Extended Data peBescription 2E Qualification Complete Definitions Extended Data Definition Extended Information Unavailable Extended Information Bytes fin Hex Rockwell Aut
86. software RSNetWorx for ControlNet EtherNet IP network RSNetWorx for EtherNet IP Alarms FactoryTalk Alarms and Events Batches or recipes FactoryTalk Batch HMI FactoryTalk View Site Edition RSLinx Enterprise software e RSView32 Various FactoryTalk services 1 See Using HMI on page 46 for additional in FactoryTalk Services Platform ormation Rockwell Automation Publication 1756 UM535D EN P November 2012 Chapter 3 Install the Enhanced Redundancy System Topic Page Before You Begin 51 Install an Enhanced Redundancy System 53 Step 1 Install the Software 53 Step 2 Install the Hardware 54 Step 3 Connect the Redundancy Modules via a Fiber optic Cable 63 Step 4 Update Redundant Chassis Firmware 67 Step 5 Designate the Primary and Secondary Chassis 71 Before You Begin Complete these tasks before you install the enhanced redundancy system e Verify that you have the components required to install your system e Read and understand the safety and environmental considerations explained in each component s installation instruction publication e Order a 1756 RMCx fiber optic communication cable if you do not have one e Ifyou choose to make your own fiber optic cable for lengths not supported by 1756 RMCx catalog numbers refer to Fiber optic Cable on page 67 Enhanced Redundancy System Quick Start Refer to these Quick Start steps when setting u
87. the RMCT ic censors corttaes ean dvawen 74 Reset the Redundancy Module eee e eee 75 Remove or Replace the Redundancy Module 75 Chapter 4 Configure the EtherNet IP Network Requested Packet Interval 2 00 eeeeeeeeeee ee eeeee tenance 77 CPU Usap Grii Biase atera te aod ata a heeranition nota area tide EEr 77 Use IP Address Swappitite cy divods tausd cucuvevbrarendie ered che iaies 77 Static versus Dynamic IP Addresses sue cue acee keen 80 Reset the IP Address for an EtherNet IP Communication Mod le scree cf i ananas a ae o a SA 80 Vse CIP SYNE aE E EA onal E E E EAAS 81 Use Produce Consume Connections 0s eens eee ee eee eee 84 Configure EtherNet IP Communication Modules in a Redundant Systemet iii sete legal chcten chet rererere 85 Before You Begin ereere r eaa aE E E E EAA 85 6 Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the ControlNet Network Configure the Redundancy Modules Table of Contents Options for Setting the IP Addresses of EtherNet IP Communication Modulesia cseseciicnancaw ae lastanaweisanaas 86 Half Full Duplex Settings fois bticten bate cea es eels ees 86 Use An Enhanced Redundancy System in a Device level Ring Topology nei weeded 4 ex gee E EEA bes EREE 87 Chapter 5 Produce Consume Connections 00ccececcececccceeenees 93 Network Update Time zcascatse f255Ss Sen sa aed tv an ate heaea ce 95 NUTs with Multiple
88. the Reserve for System Task option to allocate the entire 1 ms of the System Overhead Time Slice for service communication even if no service communication or background tasks need to be executed You might choose to use this option without service communication or background tasks to simulate a communication load on the controller during design and programming Use this setting for testing purposes only Rockwell Automation Publication 1756 UM535D EN P November 2012 Program the Redundant Controller Chapter 7 Use Periodic Tasks If you have multiple tasks in your project changing the System Overhead Time Slice does not affect how communication is serviced To increase the time to service communication when multiple tasks are used configure the periodic tasks such that more time might be available to service communication TIP While you can use multiple periodic tasks in your redundant controller program use the fewest number of tasks possible If you use periodic tasks communication is serviced any time a task is not running For example if you configure your task period at 80 ms and the task executes in 50 ms the controller has 30 ms out of every 80 ms to service communication Figure 50 Periodic Task Execution and Service Communication Task Execution 30 ms Service Communication Periodic Task Periodic Task Periodic Task If you use multiple periodic tasks verify the following e The execution time of a highest pr
89. the recommended method to connect an HMI to a redundant chassis pair if connection drops are a concern in your application In this graphic the remote chassis contains I O modules in addition to the EtherNet IP and ControlNet communication modules The I O modules are not required and included here for example purposes only Figure 5 Configuration Used to Eliminate Communication Delays on Switchover HMI Di 1756 EN2TR 1756 18160 1756 OB16D 1756 CN2R ControlNet Redundant Chassis Pair 20 20 eo 1756 RM2 1756 EN2TR 1756 CN2R 1756 RM2 1756 EN2TR 1756 CN2R 1756 L75 1756 L75 Rockwell Automation Publication 1756 UM535D EN P November 2012 37 Chapter2 Design an Enhanced Redundancy System ControlNet Networks with ControlNet networks are used to connect redundant control chassis to remote Redundant Systems I O and to other devices in the system IMPORTANT A remote chassis can be accessed over a ControlNet network using any ControlNet module that works in a nonredundant chassis with no additional firmware requirement ControlNet Network Requirements If you use a ControlNet network in your enhanced redundancy system you must take these considerations into account when using ControlNet networks in your enhanced redundancy system e Use at Least Four ControlNet Network Nodes e Assign Lowest Node Numbers to Remote ControlNet Modules
90. to Rockwell Automation are property of their respective companies Summary of Changes This publication contains new and updated information Changes throughout this revision are marked by change bars as shown to the right of this paragraph New and Updated This table contains the changes made to this publication revision Inform ation Table 1 New and Updated Information Topic Page This publication includes the addition of the 1756 RM2 A and 1756 RM2xXT modules 1756 RM2 A or 1756 RM2XT modules can only be used with other 1756 RM2 A or 1756 RM2XT modules You cannot mix 1756 RM2 A and 1756 RM2xXT modules with 1756 RM A 1756 RM B or 1756 RMXT modules References throughout the manual to specific redundancy module catalog numbers have been replaced with redundancy module This manual includes SIL2 application information 13 Features of enhanced redundancy system using 1756 RM2 A module 16 Replace 1756 RM B redundancy modules with 1756 RM2 A redundancy modules 20 without initiating a switchover Fiber channels will experience a delay during a switchover but will remain synched 1756 RM2 A restrictions 22 Added 1756 RM2 A and 1756 RM2XT information important revision information 24 changes for the 1756 RM2 A and 1756 RM2XT modules The revision has been updated wherever the 1756 L7x controller appears in this manual 27 to 19 053 Added new firmware bundles 20 054_kit1 19 053_kit1 and 19 081_ki
91. to attempt synchronization with its partner This command is available in specific conditions Available only when the chassis redundancy state is as follows Primary with Disqualified Secondary Disqualified Secondary e Unavailable dimmed in all other chassis states Synchronization is asynchronous with the execution of this command Successful execution of this command begins with synchronization which can take several minutes Monitor the chassis status displayed at the bottom of the RMCT to determine when synchronization has completed Disqualify Secondary This command forces the primary redundancy module to disqualify its partner ATTENTION Disqualifying the secondary chassis makes it unable to assume control functions that is redundancy is lost Ifyou disqualify the secondary and a major fault occurs on the remaining primary a switchover does not occur This command is available in specific conditions Available only when the chassis redundancy state is as follows Primary with Synchronized Secondary Synchronized Secondary e Unavailable dimmed in all other chassis states If you use the Disqualify Secondary command when the Auto Synchronization parameter is set to Always a synchronization attempt occurs immediately after the secondary chassis becomes disqualified To keep the secondary disqualified after issuing a Disqualify Secondary command set the Auto Synchronization parameter to
92. to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Otomasyon Ticaret A S Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 1756 UM535D EN P November 2012 Supersedes Publication 1756 UM535C EN P July 2012 Copyright 2012 Rockwell Automation Inc All rights reserved Printed in the U S A
93. to install them in an enhanced redundancy system Table 9 Installation Information for ControlLogix Chassis and Power Supplies Product Type Publication Chassis and power 1756 A4 1756 A7 1756 A10 1756 A13 1756 A17 1756 A4LXT 1756 ControlLogix Chassis and Power Supplies Installation Instructions supplies ASXT 1756 A7LXT 1756 A7XT 1756 PA72 1756 PB72 1756 PA75 1756 publication 1756 IN005 PB75 1756 PC75 1756 PH75 1756 PAXT 1756 PBXT 1756 PA75R 1756 PB75R 1756 PSCA2 For more information on using chassis and power supplies in an enhanced redundancy system see Components of an Enhanced Redundancy System on page 24 Rockwell Automation Publication 1756 UM535D EN P November 2012 55 Chapter 3 56 Install the Enhanced Redundancy System Install the Communication Modules Use the installation information provided with the communication modules to install them in an enhanced redundancy system Table 10 Communication Module Installation Product Type Cat No Publication ControlNet 1756 CN2 B communication ControlNet Modules Installation Instructions modules 1756 CN2R B publication CNET IN005 1756 CN2RXT EtherNet IP 1756 EN2T communication 1756 EN2TR modules EtherNet IP Modules Installation Instructions 1756 EN2F publication ENET IN002 1756 EN2TXT For more information on using communication modules in an enhanced redundancy system see Communication Modules in Redun
94. update the firmware for the modules in the second chassis 1 Apply power to the second chassis 2 Complete steps 3 12 in section Upgrade the Firmware in the First Chassis beginning on page 68 for the modules in the second chassis 3 Power off the second chassis after you have verified the successful upgrade ofeach module i Power on the chassis you want to designate as the primary chassis first After you tep 5 Designate the y g primary y Prim ary an d Secon d ary have applied power qualify the system so that all module pairs are at compatible Chassis firmware revision levels IMPORTANT Do not apply power to the chassis until you have read the instructions for designating the primary chassis Applying power to the chassis is crucial to designating the primary and secondary chassis Do not attempt to designate a primary chassis before loading in an application image Before you designate the primary chassis and qualify the system make sure you have the latest firmware installed See Step 4 Update Redundant Chassis Firmware on page 67 Rockwell Automation Publication 1756 UM535D EN P November 2012 71 Chapter 3 72 Install the Enhanced Redundancy System Complete these steps to designate the primary and secondary chassis of a redundant pair 1 Verify that power is removed from both chassis 2 Apply power to the chassis you want to designate as the primary chassis and wait for the module s status indicat
95. verify that you have completed these tasks e Set the Auto Synchronization option in the Configuration tab to Never e Disqualify the secondary chassis by using the Disqualify Secondary command in the Synchronization tab of the secondary redundancy module s RMCT e Updated the primary and secondary redundancy modules to compatible firmware revisions e Updated all other modules in the secondary chassis to their intended firmware revisions e Made changes to the controller project that are required to accommodate the update and replacement of modules if needed For details about completing those tasks see Step 4 Update Redundant Chassis Firmware on page 67 Rockwell Automation Publication 1756 UM535D EN P November 2012 131 Chapter6 Configure the Redundancy Modules Clicking the Lock for Update command initiates the locking process The lock can take several minutes to finish Monitor the System Update Lock Attempts log to determine when the lock is complete In addition the chassis status shown at the bottom left of the dialog box changes from Primary with Disqualified Secondary to Primary Locked for Update Figure 31 Lock for Update Status Updates Lock initiated System Update Lock Attempts System Lock History Initiation Time Status Result N 7 23 2009 17 11 36 442 In Progress Lock for update initiated at 7 23 2009 17 11 38 442 Lock complete System Update Lock Attempts System Lock History Initia
96. with enhanced redundancy ye revision 19 053 r later o use produce consume connections over an EtherNet IP network Controllers Connections let you produce broadcast and consume receive system shared tags TIP When using 1756 L7x controllers in your system you must use revision 19 053 or later Figure 21 Example System Using Produced and Consumed Tags Primary Chassis Secondary Chassis Terada 1756 EN2TR 1756 CN2R 1756 EN2TR Controller 1 Produced Tag lt 5 HO a Hg 2 N a Controller 2 z HH SHH z Consumed Tag SHH SH SAAS BAR These requirements exist when you use produced and consumed connections over an EtherNet IP network in an enhanced redundancy system revision 19 052 or later e You cannot bridge produced and consumed tags over two networks For two controllers to share produced or consumed tags both must be attached to the same network e Produced and consumed tags use connections in both the controllers and the communication modules being used e Because the use of produced and consumed tags uses connections the number of connections available for other tasks such as the exchange of I O data is reduced The number of connections available in a system depends on controller type and network communication modules used Closely track the number of produced and consumed connections to leave as many as necessary for other system tasks e You must configure both conn
97. 0 ms 100 ms 150 ms 200 ms 250 ms 300 ms 176 Rockwell Automation Publication 1756 UM535D EN P November 2012 Program the Redundant Controller Chapter 7 Minimum Value for the Watchdog Time To set Watchdog time for your 1756 L6x controllers use this table to determine which equation to use to calculate the time for each task Then use this equation Using ControlNet 1 0 ms 2 maximum_scan_time 150 Using Ethernet 1 0 ms 2 maximum _scan_time 100 The maximum _scan_time is the maximum scan time for the entire task when the secondary controller is synchronized To set the 1756 L7x initial task tuning follow these steps IMPORTANT This works only when there is no Continuous task configured in the Logix application 1 Monitor the Max Scan Time for each task while the redundant chassis pair is synchronized 2 Set the Watchdog times for each task to 3 times the Max Scan Time 3 Use the Logix5000 Task Monitor Tool to configure each Task Period 1 e Adjust the Task periods of each so that the maximum scan time is less than 80 of the task period rate e Adjust the Task periods so that the Logix CPU utilization is never above 75 e While performing these tests the HMI and any other external systems must be connected to the Logix controller IMPORTANT Verify that there are no task overlaps Download the Project Download the project only to the primary controller When the secondary control
98. 000 117 Recent Synchronization Attempts Log 0 0 0 e eee ees 118 Synchronization Status Vabsacisee nestor ones deka enews 119 Event Loge abies enaena does E E owners E E clans 120 Event G lassiticationsiicewie voxacanigssasswwed eer deepaterawas 121 Access Extended Information About an Event 5 123 Interpret an Event s Extended Information 5 124 Export Event Log Data ink xdetanessSawatnemaga nea yeesensnele 124 lenge Pauls voice Cih diate ected chal al akk tal Ae bie a cy oy 129 System Update Tab souk e tee ofan ee E S OEE tet ee 130 System Update Commands 9 72 22 penckncnladseese rererere 131 System Update Lock Attempts 2 344 i2 4s esesee avd eas 134 Locked Switchover Attempts vec ssc ccsvee ete tee aes 135 Rockwell Automation Publication 1756 UM535D EN P November 2012 7 Table of Contents Program the Redundant Controller System Bvent EUstony iia vate cleuchi sy aged ee Melati aN 136 Edit a User Comment for a System Event 2 0s 2000si00 02 137 Save System Event History 5 bade Meck eek to ee cee 137 Using Dual Fiber Ports with the 1756 RM2 A Redundancy Module 138 Fiber Channel Switchover lt 2isa sag haete hanes dvb scenewnsas 138 Configutationiiy n ci suceueO serin e nii A ee EEE aia cass 138 Monitoring and Repair isihs ti uewityenseteasehsheeaunyrtss 139 Chapter 7 Configure the Redundant Controller 0 04 4 n scdorwvveswewnenks 141 Crossloads Synchronization and Swi
99. 1 About Enhanced Redundancy Systems Topic Page Features of the ControlLogix Enhanced Redundancy System 16 Enhanced Redundancy System Components 17 Enhanced Redundancy System Operations 19 Restrictions 22 The ControlLogix Enhanced Redundancy System is a system that provides greater availability because it uses a redundant chassis pair to maintain process operation when events such as a fault on a controller occur that stop process operation on nonredundant systems The redundant chassis pair includes two synchronized ControlLogix chassis with identically specific components in each For example one redundancy module and at least one ControlNet or EtherNet IP communication module are required Controllers are typically used in enhanced redundancy systems but are not required if your application only requires communication redundancy Your application operates from a primary chassis but can switch over to the secondary chassis and components if necessary Rockwell Automation Publication 1756 UM535D EN P November 2012 15 Chapter1 About Enhanced Redundancy Systems i The software and hardware components required to configure and use a eatures of the Contro Ogix P q 8 Enhanced Redundan cy ControlLogix enhanced redundancy system provide these features System e Redundancy module speeds of up to 1000 Mbps when using a 1756 RM2 A module with another 1756 RM2 A module Redundancy module speeds up to 100 Mbps when using a 17
100. 1 1756 RM 1756 RM B REDUNDANCY NB 02 1756 EN2T 1756 EN2T A Remove S f 192 168 1 42 1756 EN2T 1756 EN2T A Driver Diagnostics Backplane 1756 44 4 Configure Driver 00 1756 L75 LOGIX5575 1756 L75 4 LO Upload EDS file From device 01 1756 RM 1756 RM B REDUNDANCY P 02 1756 EN2T 1756 EN2T A Security 39 4B_VYBP 1 1789 417 4 Virtual Chassis Device Properties Module Configuration 2 Click the Synchronization tab Module Info Configuration Synchronization Synchronizetion Status Event Log System Update System Event History Redundancy Commands synchronize Secondary Disqualify Secondary Initiate Switchover Become Primary Recent Synchronization Attempts 3 Click Initiate Switchover The Redundancy Configuration Tool dialog box opens Redundancy Configuration Tool i x Initiating a switchover transfers control from the primary chassis to the secondary chassis A short pause in control occurs during the switchover Continue switchover E ve J e 4 Click Yes The switchover begins 5 View your HMI or other status monitoring device to verify that the switchover was successful Rockwell Automation Publication 1756 UM535D EN P November 2012 195 Chapter8 Monitor and Maintain an Enhanced Redundancy System Synchronization After a Switchover TIP If your Auto Synchronization parameter is set to Alway
101. 1 0 Tags 269 Remove Other Modules from the Controller Chassis 270 Add an Identical Chassis 271 Upgrade to Enhanced Redundancy Firmware 271 Update the Controller Revision and Download the Project 271 When converting from a nonredundant to a redundant system first consider the following e You can use only RSLogix 5000 software versions 16 19 or 20 in an enhanced redundancy system e The redundant chassis pair has controller communication module and I O module restrictions See Chapter 1 for additional information Complete the tasks in this section to convert a nonredundant ControlLogix system to an enhanced redundancy system Rockwell Automation Publication 1756 UM535D EN P November 2012 265 AppendixD Convert from a Nonredundant System Update the Configuration in RSLogix 5000 Software These steps provide an overview of the process required to update the I O Configuration tree in RSLogix 5000 software 1 Ifyou have I O in the chassis with the controller add a ControlLogix communication module to the appropriate network because I O modules are not permitted in a redundant chassis 3 8 0 Configuration 1756 Backplane 1756 A fa 0 1756 L63 App_001 8 1 1 756 CN2R B CNet_chassis_0 8 2 1756 1B32 9 New Modulen J 3 1756 0B1 Ls f Paste Ctrl V Module Description E Communications 1440 ACNR A 1440 ControlNet Adapter Redundant Media 1734 ACNR A 1734 ControlNet
102. 117266 1117265 1117264 Log Time 5 4 2012 18 57 28 666 5 4 2012 18 57 27 076 5 4 2012 18 57 16 027 5 4 2012 18 57 16 027 5 4 2012 18 57 14 075 5 4 2012 18 57 14 075 5 4 2012 18 57 11 159 44 2012 18 57 11 14N Log Time 5 4 2012 18 57 11 140 5 4 2012 18 57 11 140 5 4 2012 18 57 11 120 5 4 2012 18 57 11 119 5 4 2012 18 57 11 099 5 4 2012 18 57 11 099 Partner Lag OPEN CLOSE 5 3 3 5 5 5 3 2 A lot Module Na 1756 EN2T 1756 EN2T 1756 RM 2 1756 RM2 1756 RM 2 1756 EN2T 1756 L75 17AR AM 2 Module Na 1756 AM 2 1756 AM 2 1756 AM 2 1756 AM 2 1756 AM 2 1756 AM 2 Chassis A Primary with Disqualified Secondary Futo Synchronization State Never 214 Description 34 Partner Compatible 33 Partner Ping Successful 7 Firmware error 2C Autoqualification Trigger 7 Firmware error 8 Partner Not On Same Link 35 Partner Connection Opened 91 Resnonse tn Onen Rridae Connection Description 91 Response to Open Bridge Connection 90 Request to Open Bridge Connection 91 Response to Open Bridge Connection 90 Request to Open Bridge Connection 91 Response to Open Bridge Connection 90 Request to Open Bridge Connection Expo tior Export I Classification Configuration Configuration Minor Fault Qualification Minor Fault Configuration State Changes Starts Stans Classification Starts Stops Starts Stops Starts Stops Starts Stops S
103. 3Enh Added information to enhanced redundancy module quick start Added EDS files information Added communication module installation and1756 EN2F module information Updated controller installation information Updated redundancy module installation Updated fiber optic communication cable connection Updated chassis firmware information Updated information on designating a primary and secondary chassis Updated information about conversion between nonredundant and redundant system Updated information to reset the redundant module Updated information on removing or replacing the redundant module Updated information about RPI being the same as a nonredundant chassis when using firmware revision 20 054 or later and CPU usage information for Ethernet IP communication modules Added information about unicast functionality in enhanced redundancy system remote controller Added socket support for the 1756 EN2F module for firmware revision 5 008 or later and Unicast functionality with produced consumed tags Updated information about downloading firmware bundle and determining RMCT version Updated information about 1756 L7x controller crossload time Added information about secured module mismatch Changed firmware revision information Updated MSG instructions information Updated minimum value for the Watchdog Time Changed firmware revision information
104. 4 1756 OH8l 44 1756 0N8 4 1756 OW 161 4A 1756 08174 1756 A M A 1756 SYNCH 1768 L43 1768 L45 lt Back Next gt Cancel Help c Browse to the module and select it 16 17 192 168 1 42 1756 EN2T 1756 EN2T A aa Backplane 1756 A4 A 00 1756 L73 LOGIXSS 73 1756 L73 A LOGIXS5S73 01 1756 RM21756 RM2 REDUNDANCY MODULE 02 1756 EN2T 1756 EN2T A d Click OK e Select the firmware revision to upgrade to and click Next f Click Finish The firmware begins to update When the update is complete the Update status dialog box indicates completion n ras aalas bee ayate aa Wait for the update to complete After the update completes reconnect the Ethernet cable or cables to the secondary Ethernet module and wait for communication to resume on the network Repeat steps 10 16 for all Ethernet modules that have their rotary switches set between 2 254 Rockwell Automation Publication 1756 UM535D EN P November 2012 247 AppendixC Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System 18 19 20 21 22 23 24 25 26 27 In RSLinx Classic software browse in this chassis to the primary 1756 RM module Right click to select Module Configuration to open the RMCT Click the Synchronization tab in the RMCT Module Info Configuration Synchroniza
105. 535D EN P November 2012 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C 5 From the Auto Synchronization pull down menu choose Never Module Info Configuration Synchronization Synchronization Status Event Log System Update Syste r Redundancy Module Options Auto Synchronization Always Serial Number Never 7 Name Chassis ID Conditional Description 6 Click Apply then click Yes 7 Click the Synchronization tab Module Info Configuration Synchronization Synchronization Stat r Redundancy Commands Synchronize Secondary Disqualify Secondary 8 Click Disqualify Secondary then click Yes The secondary chassis is disqualified as indicated by the RMCT at the bottom left of the RMCT and on the redundancy module s status display Status in RMCT gt Chassis A Primary with Disqualified Secondary Futo Synchronization State Never 9 Click OK Rockwell Automation Publication 1756 UM535D EN P November 2012 245 Appendix C 10 11 12 13 14 15 246 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Make a note of the primary Ethernet module s Port Configuration including the following e IP Address e Network Mask e Gateway Address General Port Configuration Network Configuration Type Static IP Address 192 168 1 4
106. 56 RM A with another 1756 RM A module and a 1756 RM B module with another 1756 RM B module e Redundant fiber ports for crossloading no single point of failure of a fiber cable e Plug and play style commissioning and configuration that does not require extensive programming e ControlNet and EtherNet IP network options for the redundant chassis pair e Easy to use fiber optic communication cable that connects redundant chassis pairs Use the same cable for the 1756 RM2 A or 1756 RM B modules e Simple redundant controller configuration by using a checkbox in the Controller Properties dialog box in RSLogix 5000 software e A redundancy system ready to accept commands and monitor the redundant system states after basic installation connection and powerup e Switchovers occur as fast as 20 ms e Support for these FactoryTalk applications for EtherNet communication modules FactoryTalk Alarms and Events FactoryTalk Batch FactoryTalk PhaseManager e Support for CIP Sync technology over an EtherNet IP network to establish time coordination across the enhanced redundant system e Access to remote I O modules over an EtherNet IP network e Access to 1715 Redundant I O systems over an EtherNet IP network e 1756 EN2T socket support 16 Rockwell Automation Publication 1756 UM535D EN P November 2012 Enhanced Redundancy System Components About Enhanced Redundancy Systems Chapter 1 Features Not Supporte
107. 56 RM B Control 1756 08 1615 44 1756 0B32 4 1756 08874 1756 OB8EI 4 1756 0W 161 4 1756 0 81 4 1756 AM ZA 1756 RM B 1756 RM2 A lt Back Next gt Cancel Help 6 Expand the network driver to locate the redundancy module or module you are upgrading LFA LUU LAU ON GLOI ECU VOVILG 17 UFTLLULMNI I A 192 168 1 41 1756 EN2T 1756 EN2T A Backplane 1756 A4 A 00 1756 L73 LOGIX5573 NSONL_Example 02 1756 EN2T 1756 EN2T A 03 1756 RM2 4 1756 RM2 REDUNDANCY MODULE E f 192 168 1 42 1756 EN2T 1756 EN2T A 7 Select the module and click OK 8 Select the firmware revision you want to update to and click Next 9 Click Finish A confirmation dialog box appears 10 Click Yes 70 Rockwell Automation Publication 1756 UM535D EN P November 2012 Install the Enhanced Redundancy System Chapter 3 IMPORTANT This can take a few minutes The system can look like it is not doing anything but itis When the update is complete the Update Status dialog box appears and indicates that the update has successfully completed ras adao bats araman 12 Verify that the redundancy module status displays PRIM indicating a successful upgrade 11 Click OK 13 Complete steps 4 12 for each module in the chassis IMPORTANT Power off the first chassis after you have verified a successful update of each module Upgrade the Firmware in the Second Chassis Complete these steps to
108. 6 35 81 83 clearing a fault 129 communication EtherNet IP delay 36 module connections 33 modules 32 communication module 52 replace 242 unicast 22 compatibility controller 30 compatible revisions 1756 RM2 A 24 1756 RM2XT A 24 components enhanced redundancy system 24 overview 17 upgrade 240 concise program 157 configuration controller 141 EtherNet IP modules 85 HMI 46 remote 1 0 44 RMCT determine if needed 106 software 49 Configuration tab 113 115 connections communication 33 controller 31 fiber optic cable 63 continuous task execution 145 recommended 145 ControlFLASH 52 69 controller 29 compatibility 30 configure redundancy 141 connections 31 differences between 1756 L6x and 1756 L7x controllers 29 enable user program 115 event in Event Log 226 installation 56 save project 102 status 201 troubleshoot nonredundant 225 use multiple 152 controller logging 189 controllers 25 Rockwell Automation Publication 1756 UM535D EN P November 2012 287 ControlNet CPU usage 198 keeper crossload 102 keeper status 101 module check status 197 monitor CPU usage 198 network update time 95 node requirements 38 40 overview 38 2 produce consume connections 93 redundant media 41 remote 1 0 18 requirements 38 sample programs 198 schedule existing network 100 new network 98 troubleshoot keeper status 216 lost connection 220 unscheduled 97 ControlNet communication modules 56 con
109. 6 UM535D EN P November 2012 Use CIP Sync Configure the EtherNet IP Network Chapter 4 Beginning with enhanced redundancy system revision 19 052 or later you can use CIP Sync technology CIP Sync technology provides a mechanism to synchronize clocks between controllers I O devices and other automation products in your architecture with minimal user intervention CIP Sync technology uses Precision Time Protocol PTP to establish a Master Slave relationship among the clocks for each CIP Sync enabled component in the system A single master clock known as the Grandmaster sets the clock to which all other devices on the network synchronize their clocks IMPORTANT Before you use this enhancement in an enhanced redundancy system revision 19 050 or later see these publications for a full understanding of CIP Sync technology in any system e Integrated Architecture and CIP Sync Configuration Application Technique publication A AT003 ControlLogix System User Manual publication 1756 UM001 Consider these points when you use CIP Sync technology in an enhanced redundancy system revision 19 052 or later e Ifyou enable CIP Sync Time Synchronization in the controllers in a redundant chassis pair you must also enable Time Synchronization in the EtherNet IP communication modules in the redundant chassis pair so all devices have a single path to the Grandmaster If time synchronization is enabled in any controller in the primary chass
110. 66563 9 14 2009 15 26 53 7 3 1756 RM2 Firmware error Minor Fault 166562 9 14 2009 15 26 53 7 3 1756 RM2 C Port2 Communication error Minor Fault 166561 9 14 2009 15 26 53 7 1756 RM 2 18 Chassis Redundancy State c State Changes 166560 9 14 2009 15 26 53 7 3 1756 RM2 31 Switchover Complete Switchover 166559 9 14 2009 15 26 53 7 3 1756 RM2 C2 Bridge Connection Deleted Starts Stops 166558 9 14 2009 15 26 53 7 3 1756 RM2 C2 Bridge Connection Deleted Starts Stops 16655 9 14 2009 15 26 53 7 3 1756 RM 2 C2 Bridge Connection Deleted Starts Stops Double click to view more information Extended Information Definition Chassis B Event Information Event Number 166561 Log Time 9 14 2009 15 26 53 707 t Event Class State Changes m Submitter Information Module Type 1756 RM 2 Slot No 3 Serial in Hex 44AA7A gt Description 18 Chassis Redundancy State changed to PWNS Extended Data Definition Extended Information Unavailable 8 View the Description and Extended Data Definitions The Description and Extended Data Definitions can be used to obtain further event information and may indicate a recovery method Rockwell Automation Publication 1756 UM535D EN P November 2012 Troubleshoot a Redundant System Chapter 9 Table 39 Possible Qualification Status Indicators Status Code Description PwQS Primary with qualified synchronized sec
111. 756 0B16D O Rockwell Automation Publication 1756 UM535D EN P November 2012 27 Chapter2 Design an Enhanced Redundancy System Redundant Chassis You can use any ControlLogix or ControlLogix XT chassis in a redundant chassis pair as long as the two chassis used are the same size For example if the primary chassis in your redundant chassis pair uses a 1756 A4 chassis the secondary chassis must use a 1756 A4 chassis You can use the 1756 A4LXT chassis with the enhanced redundancy system revision 19 052 or later For a list of the ControlLogix chassis available for use in an enhanced redundancy system see Table 4 on page 24 TIP When using 1756 L7x controllers in your system you must use revision 19 053 or later Redundant Chassis Configuration Requirements These configuration parameters must match for the components in a redundant chassis pair during normal system operation e Module type e Chassis size e Slot placement e Firmware revision e Series level See page 32 Figure 3 Example of Redundant Chassis Pair N w N w tom eS ee Geen ls arsan ma mi m A24 Allen Bradley LIET e a 222 il ae FFF i ly A N oc oc oH SAMAK AAS io ASHE HHS N y N N Da Z a aa Z Z T wo Lu ab i i LW C2 co i 7 dal de i 7 LO LO Cc ide
112. 756 1632 B IN_321 3 1756 06161 OUT_161 41756 CN2R B CNet_chassis_0 2 1756 1832 B IN_32 f 3 1756 06161 OUT_16 3 Delete the I O modules from the controller chassis configuration 0 Configuration fo New Module a 1756 Backplane 1756 fa 0 1756 L63App_ Cut Ctri x f 1 1756 CN2P B C Ra Co E Ede ControlNet Ba Copy nae b f 11756 CN2r aS Paste Ctrl V 1756 Bac Delete Del J 017 X 8 2 17 Cross Reference Ctrl E 3 17 I 41756 CN2F Properties Alt Enter WE 1756 IB32 5 IN au 8 3 1756 0B161 OUT_1 4 Continue by completing the procedures to Replace Local I O Tags and to Replace Aliases to Local I O Tags Rockwell Automation Publication 1756 UM535D EN P November 2012 267 Appendix D Convert from a Nonredundant System Replace Local I 0 Tags 268 i Replace in Routines Find Within Function Block Diagrams Ladder Diagrams Sequential Function Charts Structured Text Components Function Block Diag Ladder Diagrams Sequential Function Charts Structured Text If you have moved I O modules out of the local controller chassis and into the remote I O chassis complete these steps to find and replace the local I O tags in your program 1 Open the routine where the local I O tags need to be updated 2 Press CTRL H to open the Replace in Routines dialog box x Find What Locat z Li
113. Adapter Redundant Media 1738 ACNR A 1738 ControlNet Adapter Redundant Media 1756 CN2 A 1756 ControlNet Bridge 1756 CN2 B 1756 ControlNet Bridge 1756 CN2R 1756 ControlNet Bridge 1 B 1756 ControlNet Bridge 1756 CNB A 1756 ControlNet Bridge You can now move the I O modules to the new chassis in the I O Configuration tree 5 8 1 0 Configuration 1756 Backplane 1756 A fa 0 1756 L63 App_001 S f 1 1756 CN2R B CNet_chassis_0 es ControlNet WEI 1756 CN2R B CNet_for_lO 1756 Backplane 1756 A 5 41756 CN2R B CNet_chassis_0 f 2 1756 1B32 B IN_32 f 3 1756 OB161 OUT_16 The 1 0 can be placed in this chassis lt _ _ 266 Rockwell Automation Publication 1756 UM535D EN P November 2012 Convert from a Nonredundant System Appendix D 2 Copy the I O modules and paste them into the chassis of the newly added communication module Cut VO Configuration Copy Ctrl C 1756 Backplane o amp Paste fa 0 1756 L63 H 1 1756 CN2 Delete Del ss ControlNe H 11756 Cross Reference Ctrl E Ctrl V 175 f 41756 Properties Alt Enter WB 2 1756 IB32 0 1N 9 3 1756 0616 OUT_16 j Paste 1 0 into the new ControlNet chassis amp 0 Configuration 1756 Backplane 1756 A fa 0 1756 L63 App_001 5 1 1756 CN2P B CNet_chassis_0 s ControlNet 11756 CN2R B CNet_for_lO 3 1756 Backplane 1756 A f 0 1756 CN2R B CNet_for_lO f 2 1
114. Chassis A Event Log Time 566922 7 19 2012 10 02 45 979 566921 7 19 2012 10 02 45 759 566920 7 19 2012 10 02 45 758 566919 7 19 2012 10 02 34 120 566918 7 19 2012 10 02 34 120 566917 7 19 2012 10 02 29 153 Module Na Description Classification 1756 RM2 1E Chassis Redundancy State changed State Changes 1756 EN2TR 31 Transition To Qualified Secondary State Changes 1756 EN2TR 31 Transition To Qualified Secondary State Changes 1756 EN2TR 30 Transition To Qualifying Secondary State Changes 1756 EN2TR 30 Transition To Qualifying Secondary State Changes 1756 RM 2 91 Response to Open Bridge Connection Starts Stops zi Export Diagnostics NMONNOD Clear Fault Phaccic A Priimame mith Swnehrnized Seeandane The Export All dialog box appears x 4 e This command will collect event log records from both RMs of the redundant chassis pair 4 J This process may take several minutes 4 You will need to specify the communications path to the partner RM 4 Do you want to continue Cancel 3 Click OK Rockwell Automation Publication 1756 UM535D EN P November 2012 211 Chapter9 Troubleshoot a Redundant System The Export Event Log configuration screen appears Export Event Log x File name y Documents 825F50_chassis_B 4 07192012_1107 csy File Type Text SY Comma Separated Value I Export Diagnostic Data Export a IV Include Extended Informat
115. ControlNet Networks 4 95 Use a Scheduled or Unscheduled Network 000 c cee eens 97 Use a Scheduled Network cccccuceccccccucscueeesvas 97 Use an Unscheduled Networtle ies catiaetysetinadiaueiccamandes 97 Add Remote ControlNet Modules While Online 98 Schedule a New Network 4 u042 stactons beside gebeoatatteneaes 98 Update an Existing Scheduled Network 0 00 eee 100 Check the Network Keeper States 0c s eee eee ee eneeeeee 101 Save the Project for Each Primary Controller 4 102 Automatic Keeper Grassloads i2ciiesndzancsdddasavashacens 102 Chapter 6 About the Redundancy Module Configuration Tool RMCT 105 Determine if Further Configuration is Required 4 106 Usethe RMGC Toena Aa ace a a a er van awe eae ahead 107 Identify the RMCT Versione s sie u 20 ol Uk tat uo hele 109 Update the RMCT Versionetc step deutt eed cueautroatay 110 Module Into EADis docs na td nasties aa ara beat a aaa 111 Configuration Lab aise vito iow ceasin bean adap oe cgay 113 Auto Synchronization eiisii i rowevew he heee ee Koil esaeeerews 114 CaS SISA ins Sta ohn a hea Sealant Re eee pe here ete ad we TA 115 Enable User Program Cont0ol s sccesch cn ngucesuevassseme awe 115 Redundancy Module Date and Time eee e eee 115 Synchronization Tabi ceiavs stead dates eae ee isas 116 Commands in the Synchronization Tab 0
116. ControlNet network To schedule or reschedule your ControlNet network you put your redundant system in Program mode Use an Unscheduled Network You can use an unscheduled network when you are doing the following e Adding a new remote I O chassis of ControlLogix I O that does not use the Rack Optimized communication format That is direct connections to the I O are used e Adding a ControlLogix I O module to a chassis that has already been scheduled and uses the Rack Optimized communication format e Adding some drives that support adding I O while online e Using ControlNet to monitor HMI or the controller program You can add those components to the unscheduled network while your redundant system is online and in Run mode We recommend that you do not use an unscheduled network for all of your I O connections The use of 1756 CN2 B 1756 CN2R B and 1756 CN2RXT modules provides increased capacity for adding I O while online compared to 1756 CNB or 1756 CNBR modules With this increased capacity you can easily add I O and increase ControlNet connections used without affecting your redundant system performance Rockwell Automation Publication 1756 UM535D EN P November 2012 97 Chapter 5 Configure the ControlNet Network Schedule a New Network 98 Add Remote ControlNet Modules While Online If you are adding a remote I O chassis comprised of a ControlLogix ControlNet module and ControlLogix I O while your redundant syst
117. DANCY 20 4 Disqualified Secondary Full Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History Module he 20 53 No Partne Primary incompatibilit ooo y gt s 0 1756 EN2T A 5 8 No Partner Primary Undefined 0 1756 AM2 REDUNDANCY 20 4 No Partner Primary Incompatible Rockwell Automation Publication 1756 UM535D EN P November 2012 205 Chapter9 Troubleshoot a Redundant System Use the RMCT Event Log When troubleshooting your redundant system access the Event Log to determine the cause of an event error switchover or major fault Interpret Event Log Information Use this procedure to view and interpret Event Log information 1 Open the RMCT and click the Event Log tab f 192 168 1 41 1756 ENZT 1756 ENZT A amp Backplane 1756 44 4 f 00 1756 173 LOGIX5573 NSONL_Example Primary Chassis 02 1756 EN2T 1756 EN2T A 03 175 IA 1756 EDUNDANCY f 192 168 1 42 1756 EN2T 1756 ENZT A H 6 Backplane 1756 A4 4 00 1756 L73 LOGIX5573 NSONL_Example 02 1756 EN2T 1756 EN2T A Remove Driver Diagnostics Configure Driver Secondary Chassis load EDS file From devi y 03 1756 RM2 A 1756 RM2 REDUNDANCY mopul _UPl2ad EDS file from device Security Device Properties Module Configuration Module Info Configuration Synchronization Synchronization Status EventLog Syste
118. ER and TIMER tags Figure 40 Example Savings with the Use of an Array Controller Tags Redundancy Scope i Redundancy Show Show AIl Description Data Type Bool_Tag_1 BOOL Decimal BoolTag 2 BOOL Decimal Bool_Tag_3 BOOL Decimal Controller Tags Redundancy Scope i Redundancy Show Data Type Decimal Bool_array1 TIP If you have already created individual tags and programming that uses those tags consider changing the individual tags to alias tags that reference the elements in an array Ifyou choose to do this your programming can still reference the individual tag names but the crossload transfers the base array For more information about working with arrays User Defined Data Types and alias tags see the Logix5000 Controllers I O and Tag Data Programming Manual publication 1756 PM004 Rockwell Automation Publication 1756 UM535D EN P November 2012 Members Bool_1 Program the Redundant Controller Chapter 7 Group Data Types Together in User Defined Data Types When you create a User Defined Data Type for use in your redundancy program group like data types together Grouping like data types compresses the data size and helps reduce the amount of data transferred during a crossload Figure 41 Example of Bytes Saved by Grouping Like Data Figure 42 Data Types Data Type Size 20 byte s Figure 42
119. Errors 201 Use the RMCT for Synchronization Attempts and Status 204 Use the RMCT Event Log 206 Keeper Status Causing Synchronize Failure 216 Partner Network Connection Lost 220 Redundancy Module Connection Lost 222 Redundancy Module Missing 223 Qualification Aborted Due to a Nonredundant Controller 225 Controller Events 226 General Troublesh ooting When an error or other event occurs on the enhanced redundancy system several Tasks tasks can be executed to determine the cause After an error or event you can perform these tasks e Check the module status indicators e View diagnostic information in RSLogix 5000 software e Access status and event information in the RMCT e Use RSLinx Classic software to view network status e Use RSNetWorx for ControlNet software to view ControlNet network status Rockwell Automation Publication 1756 UM535D EN P November 2012 199 Chapter 9 Troubleshoot a Redundant System Check the Module Status Indicators 1756 L6x Controller and 1756 RM Module uy Allen Bradley If an error or event occurs in the enhanced redundancy system check the module status indicators to determine which module is causing the error or event If any of the modules have status indicators that are steady or blinking red then examine that module status display and the RMCT or other software to determine the cause Figure 58 Steady or Flashing Red Indicators that Indicate Errors on 1756 R
120. Errors on page 201 226 Rockwell Automation Publication 1756 UM535D EN P November 2012 Redundancy Module Status Indicators Appendix A Status Indicators Topic Page Redundancy Module Status Indicators 227 The redundancy modules have these diagnostic status indicators 1756 RM2 A and 1756 RM2xXT Status Indicators Figure 67 Redundancy Module Status Indicators for 1756 RM2 A and 1756 RM2XT Modules 7 Module Status Display The module status display provides diagnostic information Table 40 Module Status Display Module Status Display Description Four character display executing self test at powerup No action necessary TXxx The redundancy module is executing a self test at powerup xxx represents a hexadecimal test identification number Wait for self test to finish No action required XFER Application firmware update is in progress Wait for firmware update to finish No action is required ERAS Boot mode Erasing current redundancy module firmware PROG Flash b mode Updating redundancy module firmware Wait for firmware update to finish No action is required 222 Resolving initial redundancy module state Wait for state resolution to finish No action is required Rockwell Automation Publication 1756 UM535D EN P November 2012 227 Appendix A 228 Status Indicators Table 40 Module Status Display M
121. F Enhanced Redundancy System Checklists Topic Page Chassis Configuration Checklist 277 Remote 1 0 Checklist 278 Redundancy Module Checklist 278 ControlLogix Controller Checklist 279 ControlNet Checklist 279 EtherNet IP Module Checklist 280 Project and Programming Checklist 281 Chassis Configuration Checklist v Requirement Chassis used for the redundant pair are the same size for example both are 1756 A7 7 slot chassis Only these modules are used in the redundant chassis e ControlLogix controllers catalog numbers 1756 L61 1756 L62 1756 L63 1756 L63XT 1756 L64 1756 L65 1756 L71 1756 L72 1756 L73 1756 L73XT 1756 L74 1756 L75 ControlNet communication modules catalog numbers 1756 CN2 B 1756 CN2R B 1756 CN2RXT EtherNet IP communication modules catalog numbers 1756 EN2T 1756 EN2TXT 1756 EN2TR 1756 EN2F e Redundancy modules catalog numbers 1756 RM 1756 RMXT 1756 RM2 A 1756 RM2XT Each chassis of the pair is comprised of identical modules that are of identical redundancy firmware revisions series and memory sizes Partner modules are placed in same slots of both chassis of the redundant pair for example the 1756 L63 is placed in slot 0 of both chassis 1 0 modules are not placed in the redundant chassis Seven or fewer communication modules of any type or combination are used in each redundant chassis 1 There are some exceptions to this requirement For more in
122. G instructions during a switchover Table 30 MSG Instruction Behavior During a Switchover If the MSG instruction is From a redundant controller Then In a redundant controller any MSG instruction that is in progress during a switchover experiences an error 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 Configured Message Instructions If the MSG instruction Then originates from a redundant controller During a switchover The message instructions status bits are updated asynchronously to the program scan Consequently you cannot crossload your message instructions status bits to a secondary controller During a switchover any active message instructions become inactive When this occurs you will need to reinitialize the execution of your message instructions in the new primary controller During qualification The scrolling display changes from CMPT for compatible to Qfng for qualifying Ifa configured message is cached the primary controller automatically establishes a connection with no errors e Ifa configured message is uncached or unconnected the primary controller receives Error 1 Extended Error 301 No Buffer Memory If the message is targeted to a redundant
123. L62 1756L63 1756 L63XT 1756 L64 Revision 19 052 or later only 1756 L65 Revision 19 053 or later only 1756 L72 1756 L73 1756 L74 1756 L75 Revision 20 054 or later only 1756 L71 Rockwell Automation Publication 1756 UM535D EN P November 2012 241 AppendixC Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Replace Communication Modules You must replace all communication modules when upgrading to any enhanced redundancy system revision You must use enhanced communication modules in an enhanced redundancy system This table describes which controllers are available for system upgrades Communication Modules Available in Communication Modules Available in Standard Redundancy Systems Enhanced Redundancy Systems 1756 CNB D All revisions 1756 CNBR D 1756 CN2 B 1756 CNB E 1756 CN2R B 1756 CNBR E 1756 CN2RXT B 1756 ENBT any series All revisions 1756 EWEB any series 1756 EN2T any series 1756 EN2TXT any series Revision 19 052 or later only 1756 EN2TR any series Revision 20 054 or later only 1756 EN2F any series Replacing a 1756 EWEB Module The 1756 EWEB communication module offers functionality that is not available on other EtherNet IP communication modules When you upgrade from a nonredundant system to an enhanced redundant system your application loses functionality that is available only on the 1756 EWEB communication module These are examples of functionalit
124. LO LO Cc de N LO LO LO o 9 co lt N N is a i gt EE _ P 28 Rockwell Automation Publication 1756 UM535D EN P November 2012 Design an Enhanced Redundancy System Chapter 2 Controllers in Redundant Chassis Remember these points when placing controllers in the redundant chassis pair e Controllers are typically included but not required in enhanced redundancy systems e The differences between controller types are described in this table Table 5 Controller Features Feature 1756 L7x Controllers 1756 L6x Controllers Clock support and backup used for Energy Storage Module ESM Battery memory retention at powerdown Communication ports built in USB Serial Connections controller 500 250 Logix CPU processor Dual core Single core Memory nonvolatile Secure Digital SD card CompactFlash card Status display and status indicators Scrolling status display and four 6 status indicators status indicators Unconnected buffer defaults 20 40 max 10 40 max e You can place up to two controllers in the same chassis When you use two controllers in the same chassis they must be of the same product family For example you cannot place a1756 L6x controller and a 1756 L7x controller in the same chassis IMPORTANT When using a ControlLogix enhanced redundancy system revision 16 081 or earlier you cannot use two 1756 L64 controllers in the same chassis You can however
125. M 2 90 Requestto Open Bridge Connection Starts Stops wm wr pr 3 Open the Event Log for the secondary chassis because the cause of the switchover is not apparent Rockwell Automation Publication 1756 UM535D EN P November 2012 Troubleshoot a Redundant System Chapter 9 4 Use the time of the switchover event found in the primary chassis to identify the corresponding event in the secondary chassis The switchover indicated in the primary chassis log occurred at 10 27 08 Secondary Chassis Event Log Chassis A Classification 325811 9 25 2009 10 11 52 2 3 1756 RM 2 32 Autoqual State Change Configuration arnt CUA INO ANA ron a aare mata Ca B ES 1 om r The corresponding events in the secondary chassis log indicate that the network is not attached and that the SYS_FAIL_LActive backplane signal is active Both these events indicate an error in the connection of the ControlNet module to the network 5 Confirm the ControlNet connection error by browsing the network in RSLinx Classic software Tr A ControlNet a 01 1756 CNBRYD 1756 CNBR D 7 013 Build 004 07 1756 CN2R 1756 CN2R B 09 1756 cnor 1756 0N2P B x 7 Unable to Initialise comms path E Backplane 1756 A4iA A Error Code 0x80004005 oP 01 1756 L73 _OGIX5563 GDPOD1_AL4 02 1756 CN2R 1756 CN2R B 03 1756 RM2 Chassis B This node is no longer connected pE
126. M2 A or 1756 RM2XT Modules RUNES Evo Force 1Rs232 Allen Bradley BaT EJ Bok Figure 59 Steady of Flashing Red Indicators that Indicate Errors on 1756 RM 1756 RMXT Modules C Power RUNES E0 FORCE ERS232 Bar E ok For more information about module status indicators see Appendix A Status Indicators on page 227 Figure 60 Module Status Displays For Chassis with 1756 L6x and 1756 L7x Controllers 1756 L6x Controller and 1756 RM2 A Module Logix5563 Redu lodule EtherNeti P a O co rome aN Evo Allen Bradley derma oor mem L sox oo i ou oe CH2 CH1OK Ue E a AJET OK T 1756 L7x Controller and 1756 RM Module 1756 L7x Controller and 1756 RM2 A Module C1 Lopinss75 Redundancy Module EtherNetiIP ARA P Loginss75 Redundancy Module EtherNetiP Geateinet EE peT iow user Allen Bradley AHA Allen Bradley Uol A2 OO A os PRI COM OK ji EHZ CHI OK Ni LK oK a u a 200 Rockwell Automation Publication 1756 UM535D EN P November 2012 Troubleshoot a Redundant System Chapter 9 Use RSLogix 5000 Software To view redundancy status by using RSLogix 5000 software complete these to View Errors a 1 Go online with the redundant controller Offline J E RUN No Edits TETA Redundancy Download
127. Monitor tab note the maximum scan time Verify that the maximum scan time is smaller than the period you specified for the periodic task For most redundant applications you need to program to obtain the status of the system Program to obtain system status when you do the following e Program HMI to display the system status e Precondition logic to execute based on the system status e Use the diagnostic information to troubleshoot the system To obtain the status of your redundant system use a Get System Value GSV instruction in your program and plan for the tags you are writing the values to Rockwell Automation Publication 1756 UM535D EN P November 2012 Program the Redundant Controller Chapter 7 In the example below the GSV instruction is used to obtain the chassis ID that is the chassis A or B designation of the chassis that is functioning as the primary The PhysicalChassisID value is stored in the PRIM_Chassis_ID_Now tag The PhysicalChassisID value retrieved matches the Chassis ID indicated in the Controller Properties dialog box If the Physical Chassis ID value is Then the chassis ID is 0 Unknown 1 Chassis A 2 Chassis B Figure 51 GSV Instruction to Get Chassis ID Ladder Logic SY Get System value Class Name Redundancy Instance Name Attribute Name PhysicalChassisID Dest Prim_Chassis_ID_Now 1 Structured Text GSV REDUNDANCY PhysicalChassisID PRIN_Chassis_ID_Now Chassis ID in Co
128. NetWorx for ControlNet software from the Network menu choose Keeper Status l Network Single Pass Browse Continuous Browse 8 Online F10 Enable Edits Cancel Edits Upload from Network Download to Network Download Minimum to Network Properties 2 Verify that one keeper capable device outside the redundant chassis is indicated as active and valid 3 Verify that all of the keeper capable devices on the network are valid Keeper ous 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 BEEEEL Offline File TETT 06 NO YES Ox 304f901 13 NO YES Ox 304f901 14 NO YES Ox 304f901 4 Keeper capable devices are valid Rockwell Automation Publication 1756 UM535D EN P November 2012 101 Chapter5 Configure the ControlNet Network 4 Verify that all of the nodes on the network have the same keeper signature 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 Offline File NIA N A 0x7304901 0x7304f901 0x7304f901 0x7304f901 0x73041901 Keeper signatures are all the same Refresh Update Keeper Help
129. Network Mask 255 255 255 io Gateway Address 0 O 0 R 0 Primary Name 0 OQ D 0 Server Secondary Name oO a Server Domain Name Host Name v Auto negotiate port speed and duplex 100 X Fun duplex z Changes to Port Speed and Duplex require module reset Network Interface not Configured Current Port Speed Current Duplex Status Cancel Apply Help Disconnect the Ethernet cable or cables from the secondary Ethernet module Remove the secondary Ethernet module from the secondary chassis Record the original rotary switch settings as you need to set them back later Set the rotary switches to 999 Reinsert the secondary Ethernet module into the secondary chassis Bridging across the backplane or via the Ethernet module s USB port configure the secondary Ethernet module s Port Configuration to match the primary Ethernet module s Port Configuration from step 10 Update the secondary Ethernet module to firmware revision 5 008 by following these steps a Launch ControlFLASH software and click Next Rockwell Automation Publication 1756 UM535D EN P November 2012 Secondary Chassis p Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C b Select the Ethernet module catalog number and click Next Enter the catalog number of the target device fi 756 AM B 1756 0B161574 1756 0B32 4 1756 0B8 4 1756 OB8EI 4 1756 0087
130. P November 2012 193 Chapter 8 Monitor and Maintain an Enhanced Redundancy System Check Qualification Status via the RMCT To determine the qualification status of your system by using the RMCT open the RMCT and view the qualification status in the bottom left corner of the tool Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History r Redundancy Module Options Auto Synchronization Chassis ID M Enable User Program Control pwys Chassis B Serial Number 00856DE2 Name Description Location r Redundancy Module Date and Time 107 4 2012 Current Date Date Format Apply Workstation Time dd mm yypy 4 17 55PM_ Current Time tmm dd pyyy Chassis B Primary with Synchronized Secondary Auto Synchronization State Aways 194 CH1 Status Active CH2 Status Redundant Chassis Platform Configuration Enhanced Rockwell Automation Publication 1756 UM535D EN P November 2012 Monitor and Maintain an Enhanced Redundancy System Chapter 8 Conduct a Test Switchover Complete these steps to verify that your redundant system switches over as expected Your system must be fully qualified before you begin 1 In RSLinx Classic software access the RMCT for the primary redundancy module F 192 168 1 41 1756 EN2T 1756 EN2T A Back 5 00 1756 L75 LOGIX5575 1756 L75 4 LOGIX5575 0
131. Qualification Qualification Auto Qualification n alet Final attempt to Auto Qualification In ETETE Commanded Commanded Auto Qualification Synchronized Qualification Complete Auto Qualification In Progress Auto Qualification Module Com Commanded _ Auto Qualification Synchronized Qualification Complete Accent Edit Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Redundancy Modules Chapter 6 Edit a User Comment for a System Event To edit the User Comment associated with a system event select the event and then click Edit Then type your event description and click Accept Edit Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History m Event History Extended Info A Extended Info 8 Us Qualific ation Auto 0 Syn ichronized Qualific ation 10 4 201 2 Qualification Auto 0 in Progress User Comment N 1 N 2 10 4 2012 Qualification Auto O Qual eet N 3 10 4 2012 Disqualification Comma E N 4 10 4 2012 Qualification uto 0 eored Qualification N 5 10 4 2012 Qualification Auto O In eee N 6 10 4 2012 Disqualification Comma N 7 1073 2012 Qualification uto 0 5 horiec Qualification N 8 10 3 2012 Qualification Auto Q In Progress lt vi iiij gt Accept Edi Cancel Edit Description
132. Retain Test Edits on Switchover setting at the default that is unchcecked to avoid faulting both controllers when testing your edits Ifyou enable the system to retain the test edits on a switchover that is you check Retain Test Edits on Switchover faults that result from the test edits can also occur on the new primary controller after a switchover If you do not enable the system to retain the test edits on a switchover that is you leave Retain Test Edits on Switchover unchecked faults that result from the test edits are not carried over to the new primary controller in the event of a switchover Rockwell Automation Publication 1756 UM535D EN P November 2012 183 Chapter7 Program the Redundant Controller Use this table to determine the Retain Test Edits on Switchover setting that suits your application If you need to Prevent a test edit from faulting both the primary and secondary Leave Retain Test Edits on Switchover controller unchecked Keep test edits active even in the event of a switchover and at the risk Check Retain Test Edits on Switchover of faulting both controllers To change the Retain Test Edits on Switchover setting click the Redundancy tab in the Controller Properties then click Advanced Figure 56 Retain Test Edits on Switchover f Controller Properties Redundancy_update General Major Faults Minor Faults Date Time Advanced SFC Execution File Redundancy Nonvolatile Memory M
133. Revision 19 052 or Later 008 IP Address Swappiiie 0 vocetevvacne Ci ess wlth mine he ches Unicast Functionality 6cc co e ein rice abel eae eae eases Possible Communication Delays on EtherNet IP Networks ControlNet Networks with Redundant Systems 00 ControlNet Network Requirements 0 2c eee eee eee Redundant GontrolNet Media i csc4adsa ede igen ed Other Communication Networksin 22 cnncecey ideas eiecn mes Firmware Requirements 4 50 ox eisai 5 sb ia cok Veeuge S35 F 4 Software Requirements lt c206seicauadeeen ack prree nde auoeeent Required Software vs sic 4 aves os heute Ltt e hoy ed one Optional Sobwares c1ah secure aan pate babe ew uae Chapter 3 Before You Begin asiaa biaa volte chain stu tas a cl lie Enhanced Redundancy System Quick Start o n asees Install an Enhanced Redundancy System 0 2 0 sees eee ee ee Step 1 Install the Software wsc2c2iessehig Lice seepes teases dies Rockwell Automation Publication 1756 UM535D EN P November 2012 Table of Contents Install the Sottwiteushii nue aas eer esG dude alee 53 Add the EDS Filesi aetants chen tee a a aa aah 54 Step 2 Install the Hardware neussuneeeeeernrrerrrr reren 54 Install the First Chassis and its Components n s aseeseen 54 Install the Chassis and Power Supply 02 cess cence eee 55 Install the Communication Modules 0 cece e cece eee 56 Install a Controller cccrve
134. Shift Instructions are used these system behaviors may result 1 Ifa higher priority task interrupts one of the Array File Shift instructions the partially shifted array values are crossloaded to the secondary controller 2 Ifa switchover occurs before the instruction completes its execution data remains only partially shifted 3 After a switchover the secondary controller starts its executing at the beginning of the program When it reaches the partially executed instruction it shifts the data again Rockwell Automation Publication 1756 UM535D EN P November 2012 159 Chapter 7 160 photoeye Program the Redundant Controller Copy File Source Dest Length co Buffering Critical Data Ifyou cannot place Array File Shift instructions in the highest priority task consider using a buffer with Copy File COP and Synchronous Copy File CPS instructions to maintain the integrity of the array of data The programming example shown here shows the use of a COP instruction to move data into a buffer array The BSL instruction uses the data in that buffer array The CPS instruction updates the array tag and maintains data integrity because it cannot be interrupted by a higher priority task If a switchover occurs the source data that is the array tag remains unaffected Figure 46 Using a Buffer to Maintain Data During Shift BSL Bit Shift Left Array Control BSL Source Bit input_bit
135. T Ethernet communication modules that have rotary switches set must have been previously updated using Upgrade Ethernet Modules When Rotary Switches Are Set between 2 2540n page 244 Once you have upgraded the firmware for each module in the secondary chassis prepare the RSLogix 5000 project for the upgrade Step 9 Prepare the RSLogix 5000 Project for the Upgrade Complete these steps to prepare the RSLogix 5000 program and controllers for the upgrade 1 2 Launch RSLogix 5000 software and go online with the primary controller Verify that the watchdog time is set to a value that corresponds with the requirements of the enhanced redundancy system revision and your application See Minimum Value for the Watchdog Time on page 177 for information about calculating the minimum watchdog time 3 Cancel or assemble any pending test edits Remove all Sequential Function Chart SFC forces from the project Verify that no changes need to be made to the following I O forces I O configuration After this step changes to I O cannot be made until after the enhanced redundancy system revision upgrade is complete and both chassis are synchronized Ifyou are upgrading an enhanced redundancy system revision 16 81 or earlier disable CST Mastership Configure the controllers and communication modules in the redundant chassis pair as necessary 8 Save the project 9 Go offlin
136. UM535D EN P November 2012 Program the Redundant Controller Chapter 7 Use Concise Programming Use these recommendations to create concise programming Using concise programming makes your program execute faster and reduces your program scan time Execute an Instruction Only when Needed We recommend that you execute instructions only when needed because each time an instruction writes a value to a tag the tag is crossloaded to the secondary controller Even if the tag values is the same it is rewritten and is therefore crossloaded Because many instructions write tag values whenever executed strategic and economical use of instructions is needed Strategic programming techniques include the following e Using preconditions to limit the execution of instructions e Combining preconditions when possible e Dividing programming into subroutines that are called only when required e Running noncritical code every 2 or 3 scans instead of during every scan For example precondition an ADD instruction to run only when the controller gets new data As a result the Dest_Tag is crossloaded only when the ADD instruction produces a new value Figure 44 Precondition Used with ADD Instruction DD New_Data Add Source Tag_1 Source B Dest Dest_Tag pe Rockwell Automation Publication 1756 UM535D EN P November 2012 157 Chapter 7 158 Program the Redundant Controller In addition to using
137. User Manual Allen Bradley ControlLogix Enhanced Redundancy System Catalog Numbers 1756 RM 1756 RMXT 1756 RM2 1756 RM2XT Allen Bradley Rockwell Software 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 L 1 available from your local Rockwell Automation sales office or online at http www rockwellautomation com literature 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 No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment
138. X 10 1756 CN2R 1756 CN2P B Backplane 1756 A4 A An attempt to access the cb X 01 1756 L73LOGIX5563 GDPOD1_ALARMS secondary RMCT fails and this error is indicated 02 1756 CN2R a 22 03 1756 RM2 Chassis B Rockwell Automation Publication 1756 UM535D EN P November 2012 221 Chapter 9 Troubleshoot a Redundant System Redundancy Module Connection Lost 222 Chassis A To recover from a ControlNet network disconnection take these actions e Check all ControlNet tap and trunkline connections Correct any disconnections or other connection anomalies e Ifthe Auto Synchronization parameter is not set to Always use the commands in the Synchronization tab of the RMCT to synchronize your chassis For more information about troubleshooting ControlNet network anomalies see the ControlNet Modules in Logix5000 Control System User Manual publication CNET UMO01 To recover from a EtherNet IP network disconnection take these actions e Check all EtherNet IP network and switch connections e Ifthe Auto Synchronization parameter is not set to Always use the commands in the Synchronization tab of the RMCT to synchronize your chassis For more information about troubleshooting EtherNet IP network anomalies see the EtherNet IP Modules in Logix5000 Control System User Manual publication ENET UMO001 To determine if the connection between the redundancy modules caused a switchover or state change
139. ack Connection None Rack Connection None zi Time Sync Connection None Time Sync Connection None i con Hee Status Creating OK Cancel Help a TIP If you are unable to specify the new revision you may need to change the Electronic Keying parameter to Compatible Keying 16 Save the project 17 Download the project to the secondary controller The secondary controller is at the higher network address of the two available for the redundant chassis Offline J F RUN No Forces Go Online No Edits Upload Redundancy b a Controller Redun Program Mode 18 After the download is complete go offline Rockwell Automation Publication 1756 UM535D EN P November 2012 259 Appendix C Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System You are now ready to lock the system and initiate a locked switchover to update the primary chassis Continue with Step 10 Lock the System and Initiate a Switchover to Upgrade Step 10 Lock the System and Initiate a Switchover to Upgrade Once you have downloaded the RSLogix 5000 project you prepared complete these steps to lock your system and initiate a switchover IMPORTANT Remain offline while completing these steps e Once you have locked the system do not abort the system lock Aborting the system lock during this procedure clears the project from the secondary controller e Do not
140. al memory you can load the most recent project back onto that controller If you store the same project on both controllers nonvolatile memory cards while the process is running you must save the project on the controllers while they are in the secondary controller state To do so you save the project on the secondary controller conduct a switchover and save the project on the new secondary controller For more information see the steps below 178 Rockwell Automation Publication 1756 UM535D EN P November 2012 Program the Redundant Controller Chapter 7 Store a Project While the Controller is in Program or Remote Program Mode If you want to store your controller project in nonvolatile memory while your redundant system is not running complete these steps Before you begin verify that a controller communication path has been specified and that you are able to go online with the primary controller 1 Verify that the redundant chassis are synchronized If they are not synchronized synchronize them 2 Use RSLogix 5000 software or the mode switch to put the primary controller into Program or Remote Program mode 3 In RSLinx Classic communication software right click the 1756 RM module and choose Module Configuration to open the RMCT 192 168 1 41 1756 EN2T 1756 EN2T A amp Backplane 1756 A4 4 00 1756 L73 LOGIXS573 NSONL_Example 02 1756 EN2T 1756 EN2T A 03 1756 1756 RM2 REDUNDANCY MODUL f
141. an be accessed over an EtherNet IP network using any EtherNet IP module that works in a nonredundant chassis with no additional firmware requirement with the following exception If the remote chassis contains a controller consuming a tag produced in the RCP it can only consume the tag with the required firmware revisions listed in Table 7 Table 7 EtherNet IP Communication Modules in Remote Chassis Minimum Firmware Requirements EtherNet IP Communication Module in Remote Minimum Firmware Revision Chassis 1756 EN2F 4 003 1756 EN2T 1756 EN2TR a2 1756 EN3TR 1756 ENBT 6 001 1768 ENBT 4 001 1769 L2x 19 011 1769 L3xE 1788 ENBT 3 001 For more information on using an EtherNet IP network in your enhanced redundancy system see Chapter 5 Configure the ControlNet Network on page 93 EtherNet IP Network Features in an Enhanced Redundancy System Revision 19 052 or Later In an enhanced redundancy system revision 19 052 or later you can execute these tasks on an EtherNet IP network e Use 1756 EN2TR modules e Connect to remote I O modules e Connect to 1715 Redundant I O systems e Use produce consume tags e Connect toa Device level Ring networks e Use CIP Sync technology The rest of the topics in this section apply to all enhanced redundancy systems Rockwell Automation Publication 1756 UM535D EN P November 2012 35 Chapter 2 36 Design an Enhanced Redundancy System IP Address Swapping E
142. ancy System Controller Logging AN AERE ane Pee A E EA tg a Sag atte Sena baron Brie eased 189 Controlle Log oiir dy wie aok eee ey are ark aoa A eases deed 190 Controller Logging in Enhanced Redundancy Systems 190 Use Programming to Monitor System Status 0 eee eee 190 Verify Date atid Time Settings yi 4 eat wotod Sta coeina eens ve ueked 191 Verify System Oualtication 2vaegi tid ceo eace errereen 192 Check Qualification Status via Module Status Displays 192 Check Qualification Status via the RMCT 000 eee 194 Conduct a Test Switchover ssictivece i fer dhce ciulcinwnetagears 195 Synchronization After a Switchover cee ee ee eee ees 196 Check the ControlNet Module Status 00 cece scene eee ee 197 COP Sate ec cd sich S cara aha ie kh ell el Ate beh a ah alee he lace 198 C nections Used scented idan tae a O E TEREE OS 198 Monitor the ControlNet Network 00 ce eee ee 198 Chapter 9 Troubleshoot a Redundant System General Troubleshooting Tasks 2 eee eeeeee eee eneeees 199 Check the Module Status Indicators 00 cee eee cence ee eee 200 Use RSLogix 5000 Software to View Errors 0 0 eee eee 201 Redundant Controller Major Fault Codes 008 203 Use the RMCT for Synchronization Attempts and Status 204 Recent Synchronization Attempts iniavsgrseekawsdiaes canes 204 Module level Synchronization Status
143. and module processes have started or stopped No corrective action is required er gt a a ifan event that is classified as a Failure State Change or Major ae EST Fed s after the Starts Stops event view the Extended Event IS loganaisaian 2 IBENAT info fition of both events to determine if the events are related State Changes A chassis or module state change has occurred No corrective action is required For example if the chassis designation changes from being a However if an event that is classified as a Failure or Major Fault occurs after disqualified secondary to a qualified secondary a State Change event is the State Changes event view the Extended Event Information of both logged events to determine if the events are related Switchover An event related to a chassis switchover has occurred Action can be required to determine the cause of the switchover and For example if an Initiate Switchover command is issued an event potential correction methods classified as Switchover is logged Double click the event to see Extended Event Information and the suggested recovery method if applicable Synchronization An event related to chassis synchronization has occurred No corrective action is required 122 For example if the Synchronization command has been issued a Network Transitioned to Attached event is logged and classified as Synchronization This event is provided for informational purposes and does not indicates
144. any open RMCT sessions connected to the current redundancy modules being replaced Remove the redundancy module pair in any order from the redundant chassis Insert the 1756 RM2 A redundancy module pair in any order in the redundant chassis into the same slots as the redundancy modules Ifnot already installed install the EDS file for the 1756 RM2 A module by uploading it from the module by using RSLinx Classic software If needed obtain the EDS file for the 1756 RM2 A module Right click on the module in RSWho and select Upload EDS file from device Update to the appropriate firmware revision in the primary and secondary 1756 RM2 A modules Reconnect the fiber cable on either CH1 or CH2 of the 1756 RM2 A redundancy module Optional Connect a second fiber cable on the remaining channel if fiber redundancy is desired Wait for at least 45 seconds after connecting one of the fiber cables Launch the RMCT again for the newly installed 1756 RM2 A modules Set the Auto Synchronization option in the Configuration tab back to the original value or to a new desired value Using the RMCT synchronize the system again if it is not already qualified 264 Rockwell Automation Publication 1756 UM535D EN P November 2012 Appendix D Convert from a Nonredundant System Topic Page Update the Configuration in RSLogix 5000 Software 266 Replace Local 1 0 Tags 268 Replace Aliases to Local
145. at the network cable of the module is disconnected or broken The event log shows Transition to Not Lonely when you reconnect the cable Unicast not supported A unicast connection is configured in the redundant controller and enhanced redundancy systems do not support Unicast Unknown event The 1756 RM configuration tool may be an older version and must be updated WCT time change gt 1 second 238 The clock of the 1756 RM changed This happens when you use the RMCT to set the clock e connect the redundancy module to another redundancy module that is already the primary The redundancy module synchronizes its clock to that of the primary 1756 RM Rockwell Automation Publication 1756 UM535D EN P November 2012 Upgrade from a Standard Redundancy System Appendix C Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Topic Page Upgrade from a Standard Redundancy System 239 Upgrade System Components 240 Upgrade Ethernet Modules When Rotary Switches Are Set between 2 254 244 Upgrade the System Software 241 Upgrade by Using Redundancy System Update 250 Replace 1756 RM A or 1756 RM B Redundancy Modules with 1756 RM2 A 264 Redundancy Modules If you need to upgrade your standard redundancy system to an enhanced redundancy system complete this procedure Before You Begin Before you begin upgrading from a standard redundancy system to an enhanced redunda
146. ata for a single or multiple event that occurs on a primary or secondary redundancy module Complete these steps to export event data for a single event TIP Ifthe redundancy modules are not available in RSLinx Classic software after a fault you must apply the recovery method indicated by the module before attempting to export the Event Log data 1 Launch RSLinx Classic communication software and browse to the redundancy modules 2 Right click the primary redundancy module and choose Module Configuration 124 Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Redundancy Modules Chapter 6 3 In the Auto Update area click Off to keep the log from updating m Auto Update C ON OFF 4 In the Partner Log area click Close This closes the event log of the partner module m Partner Log C OPEN CLOSE 5 Select a single event or multiple events for which you want to export data To select multiple events select a start event press SHIFT and select an end event Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History Auto Update _ Partner Log ON OFF l C OPEN CLOSE Export Selection Export AII Chassis Log Time Slot Module Na Description 11 11 2010 13 54 00 671 1756 A 14 Chassis Redundancy State changed to PWDS State C 179 11 11 2010 13 54 00 652 5 1756 EN2T
147. ation Publication 1756 UM535D EN P November 2012 Monitor and Maintain an Enhanced Redundancy System Chapter 8 Verify Date and Time After you have completed programming your redundant system and have Settin gs downloaded your program to the primary controller check the Redundancy Module Date and Time information and verify it matches the date and time of your system TIP Consider checking the Redundancy Module Date and Time as a part of your regular maintenance procedures Verifying the date and time information on a regular basis keeps the event logs of the redundancy modules accurate If the date and time are not correct the redundant system event logs will not match the date and time information for the rest of the system Incorrect date and time information complicates troubleshooting if an event or error occurs on your redundant system Module Info Configuration Synchronization Synchronization Status EventLog System Update System m Redundancy Module Options Auto Synchronization Always v Serial Number Name Chassis ID Chassis B v Enhanced Redundancy Chassis B Description This is the 1756 RM module in chassis B Jv Enable User Program Control ERIEN Quadrant 4 A Redundancy Module Date and Time Current Date 97 9 2009 Current Time 10 11 21 AM Verify Date and Time Settings Date Format C ddimmAyyy mmddyy Apply Workstation Time IMPORTANT If power to one of the redunda
148. ation Stetus Event Log System Update System Event History Redundancy Commands Synchronize Secondary Disqualify Secondary m Recent Synchronization Attempts Initiate Switchover Become Primary Order Result N Success a N 1 Success N 2 Success N 3 Synchronization not attempted Refresh Description Select an entry in the Recent Synchronization Attempt list to see Details a 4 U Remove the new secondary Ethernet module from the chassis and reset the rotary switches back to their original setting from 999 Reinsert the secondary Ethernet module back in the chassis and wait until network communication resumes Repeat steps 35 36 for all Ethernet modules that have their rotary switches set between 2 254 Rockwell Automation Publication 1756 UM535D EN P November 2012 249 AppendixC Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Upgrade by Using Redundancy You can upgrade an jee eee ie Hau to ete ne a Syst em Up date process continues to run This is known as Redundancy System Update IMPORTANT RSUis available only when upgrading from an enhanced redundancy system revision to another You cannot use this process to upgrade from a standard redundancy system to an enhanced redundancy system IMPORTANT Any Ethernet communication modules that have the rotary switch set must first be updated using the Upgrade Ethernet Mod
149. ation about interpreting the Recent Synchronization attempts log see Recent Synchronization Attempts Log on page 118 Rockwell Automation Publication 1756 UM535D EN P November 2012 Troubleshoot a Redundant System Chapter 9 Primary Chassis Secondary Chassis Primary Chassis Secondary Chassis Module level Synchronization Status The Synchronization Status tab provides a module level view of redundant chassis and can be used to identify what module pair may be causing a synchronization failure Depending on the type of synchronization failure you may need to open the Synchronization Status tabs for the primary and secondary redundancy modules e Ifthere is a difference between major revisions of the controllers modules the Compatibility column shows Undefined as shown in this graphic No Partner Primary Undefined 0 54 2 0 1756 EN2T 7A 5 8 No Partner Primary Undefined 3 0 1756 AM2 REDUNDANCY 20 4 No Partner Primary Incompatible Module Revision Secondary Readiness State Compatibility 1756 EN2T 7A 5 8 No Partner Secondary Undefined 1756 RM2 REDUNDANCY 20 4 Disqualified Secondary Full N oo e Ifthere is a difference between minor revisions of the controllers the Compatibility column shows Incompatible as shown below Module Revision Secondary Readiness State __ Compatibility Secondary Incompatibility 2 0 1756 EN2T A 5 8 No Partner Secondary Undefined 3 0 1756 RM2 REDUN
150. ation modules in the redundant chassis are not used while the system is running online At least four ControlNet nodes are used on the ControlNet network That is at least two ControlNet nodes are on the ControlNet network in addition to the two ControlNet modules in the redundant chassis These requirements apply to at least one ControlNet node e Itis notin the redundant chassis pair It uses anode address lower than the ControlNet node addresses of modules in redundant chassis pair These requirements apply to all ControlNet communication modules available in an enhanced redundancy systems ControlNet module partners in the redundant chassis have the following e Node address switches set to the same address for example both modules switches are set to node address 13 e Two consecutive node addresses reserved for example nodes 13 and 14 to accommodate a switchover The primary ControlNet module can have an even or odd numbered node address The ControlNet network is scheduled by using techniques described in the ControlNet Modules in Logix5000 Control Systems User Manual publication CNET UM001 M Devices on other communication networks are bridged to the ControlNet network appropriately Rockwell Automation Publication 1756 UM535D EN P November 2012 279 AppendixF Enhanced Redundancy System Checklists v Requirement ControlNet HMI A ControlNet network or a ControlNet to EtherNet IP gateway is use
151. ber channel switchover to the REDUNDANT channel provided the REDUNDANT channel is still operating in a normal condition e Signal attenuation along the fiber cable path routed between the partner redundancy modules e A broken or damaged fiber cable routed between the partner redundancy modules e Improper or loosely fit cable connector e SFP transceiver fault e Removal or loose connection of the SFP transceiver e Data communication error signalled by a failed CRC check Chassis synchronization is lost only when both of the channels have failed or are disconnected The fiber channel switchover may occasionally extend the completion of data communication packets between the partner redundancy modules Therefore the controller s scan time may occasionally experience a delay of 10 ms or less Configuration The use of dual fiber ports is entirely plug amp play There is no user configuration needed for any of the operations of the active and redundant channels The firmware automatically manages the selection of active and redundant channels The dual fiber cables between the partner redundancy modules can be crossed over between CH1 and CH2 without any restriction 138 Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Redundancy Modules Chapter 6 Monitoring and Repair Synchronization is preserved if the REDUNDANT channel has failed or is being repaired The repair of the REDUNDANT channel can b
152. c Lasks aiviere ha taeddigi fee ieee a2 167 Program to Obtain System Status jcve cscaescees swank ieee esnneeate 168 Program Logic to Run After a Switchover 0 00 cee eee eee 170 Use Messages for Redundancy Commands 0 0 000 eee 171 Verify User Program Control i2us 2o4 elo seviwosndad 5aeys bohat 171 Use an Unconnected Messages coicipaseeenivoteue wend es uaeiees 171 Configure the MSG Instruction u cacsnsia sass ntantusbinwid eararires 172 Set the Task Watchdog vsvaviewsetineintie bi aiwdpioe es eboannbni 175 Minimum Value for the Watchdog Time 00005 177 Download the Project 205 29 usetnbn 05 sSsanteneecaee tysiees chases 177 Store a Redundancy Project to Nonvolatile Memory 178 Store a Project While the Controller is in Program or Remote Program Mode is tisc eck asada seta nee eee wae 179 Store a Project While a System is Running 08 181 Rockwell Automation Publication 1756 UM535D EN P November 2012 Table of Contents Load a PROVeCti asserts lees eines VIG alee eee aN 182 Online Edits tiisna eren teas Verein nRa E ae 182 Support for Partial Import Online nosne 182 Plan for TeseEdits eirinen raae E E EE 183 Finalize Edits with Caation 4 25 422 ecead vakeseteenheeatwone 186 Reserve Memory for Tags and Logic 0 0 0 cee sees a ee 187 Chapter 8 Monitor and Maintain an Enhanced Tasks to Monitor the System ceceeeeeeeeeeeeeeeeeees 189 Redund
153. cation Module Table 36 Qualifying System Primary Chassis Display Secondary Chassis Display Redundancy Module Communication Module Redundancy Module Communication Module PRIM and QFNG Table 37 System with a Primary and Disqualified Secondary Primary Chassis Display Secondary Chassis Display Redundancy Module Communication Module Redundancy Module Communication Module PRIM Either e CMPT modules are compatible DSNP no partner is present 192 Rockwell Automation Publication 1756 UM535D EN P November 2012 Monitor and Maintain an Enhanced Redundancy System Chapter 8 Qualified Redundant Chassis Example of Qualified and Disqualified Status Indicators This example shows status display messages and status indicators that may appear differently depending on the qualification status of the redundant chassis Note that these are only two examples of many possible status display message and indicator combinations for both the qualified and disqualified states Disqualified Redundant Chassis
154. cee eee eee ee 205 Use the RMCT Event Lop ics ccc tase 39 dann Voeree evans ss49 4 206 Interpret Event Log Information 4 asnsaais ite pentcsteatbtewagorseaceg 206 Export All Event Logs sce codes ewidnad Lidiwd pi eeleraaed Riad 211 Export Diagnostics sereine oeron iarri tr eeu E REEERE 214 Contact Rockwell Automation Technical Support 216 Keeper Status Causing Synchronize Failure 00 000005 216 Check the Module Status Display cdcocsie coin totwenweed ata 217 Check Keeper Status in RSNet Worx for ControlNet Software 217 Valid Keeper Status and Signatures tonite she nwaw ndaegaamuns 218 Partner Network Connection Lost occgeckii ee dani aivade ta daevees 220 Redundancy Module Connection Lost 00sec cece ee eens 222 Redundancy Module Missing 2625 02 62 c0e vows ene ven edn es ce Rne sie 223 Qualification Aborted Due to a Nonredundant Controller 225 Contioller Eventseris sre E r nate eddy tase A EA 226 Rockwell Automation Publication 1756 UM535D EN P November 2012 9 Table of Contents Status Indicators Event Log Descriptions Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Convert from a Nonredundant System Redundancy Object Attributes Enhanced Redundancy System Checklists Appendix A Redundancy Module Status Indicators 1756 RM2 A and 1756 RM2XT Status Indicators 1756 RM A and 1756 RM B Status Indicators Redundancy Module Fault
155. ctionality specific to that module in an enhanced redundancy system You can use a maximum of 2 controllers and 7 ControlNet or EtherNet IP communication modules in each chassis of a redundant chassis pair In enhanced redundancy systems revision 16 081 and earlier only EtherNet IP communication modules cannot execute these tasks Connect to remote I O over an EtherNet IP network Connect to 1715 Redundant I O systems Use Produce Consume tags Connect to Device level Ring networks Use CIP Sync technology You can execute the tasks mentioned above in an enhanced redundancy system revision 19 052 or later 22 Rockwell Automation Publication 1756 UM535D EN P November 2012 Chapter 2 Design an Enhanced Redundancy System Topic Page Components of an Enhanced Redundancy System 24 Redundant Chassis 28 Controllers in Redundant Chassis 29 Redundancy Modules in Redundant Chassis 31 Communication Modules in Redundant Chassis 32 Power Supplies and Redundant Power Supplies in Enhanced Redundancy Systems 34 ControlNet Networks with Redundant Systems 38 Other Communication Networks 42 Other Communication Networks 42 1 0 Placement 44 1715 Redundant 1 0 Systems 44 Using HMI 46 Firmware Requirements 49 Software Requirements 49 This chapter explains how to use the required and optional components to design an enhanced redundancy system Rockwell Automation Publication 1756 UM535D EN P
156. cy enabled Once the redundant chassis pair contains all desired components including controllers configured for redundancy and are powered no further tasks are required in the redundancy modules to activate system redundancy The redundancy modules automatically determine the operational state of each of the chassis pair and are ready to accept commands and provide system monitoring Rockwell Automation Publication 1756 UM535D EN P November 2012 31 Chapter2 Design an Enhanced Redundancy System Communication Modules in Redundant Chassis Remember these points when placing ControlLogix ControlNet and EtherNet IP communication modules in the redundant chassis pair e You must use enhanced communication modules in enhanced redundancy systems Enhanced communication modules contain a 2 in their catalog number For example the 1756 EN2T module Standard ControlNet and EtherNet IP communication modules are not supported e Youcan use the 1756 EN2TR module only with an enhanced redundancy system revision 19 052 or later e You can use any combination of up to seven enhanced communication modules in each redundant chassis e Ifyou use a ControlNet network in your redundant chassis pair you must have two ControlNet communication modules outside the redundant chassis pair When assigning node address numbers assign the lowest node number address to a ControlNet communication module outside the redundant chassis pair For more
157. cy module firmware that is currently installed If you upgrade your RMCT version but do not upgrade your redundancy module firmware revision compatible with the new RMCT version the About dialog box may not reflect the new RMCT version Step 5 Add the EDS Files If needed obtain EDS files for modules in your system from the Rockwell Automation website at http www rockwellautomation com resources eds Once you have downloaded the required EDS file launch the EDS Hardware Configuration Tool by choosing Start gt Programs gt Rockwell Software gt RSLinx Tools gt EDS Hardware Installation Tool The tool then prompts you to Add or Remove EDS files Rockwell Automation Publication 1756 UM535D EN P November 2012 253 AppendixC Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Step 6 Prepare the Redundant Chassis for the Firmware Upgrade Complete these steps to prepare both the primary and secondary redundant chassis for redundancy firmware upgrades 1 Set the mode switch of the primary and secondary controllers to REM If the redundant controllers in both chassis of the redundant chassis pair are not in Remote Program REM mode the redundancy firmware upgrade cannot be completed 2 Open RSLinx Classic software and browse to the redundancy module 3 Right click the redundancy module and select Module Configuration to open the RMCT 4 192 168 1 41 1756 EN2T 1756 EN2T A
158. d Any motion feature Any SIL3 functional safety feature within the redundancy controllers Firmware Supervisor Event Tasks Firmware revision 19 052 for 1756 L7x controller IMPORTANT For Ethernet modules signed and unsigned firmware are available Signed modules provide the assurance that only validated firmware can be upgraded into a module Signed and unsigned firmware Both signed and unsigned firmware are available Product is shipped with unsigned firmware To obtain signed firmware you must upgrade your product s firmware To obtain signed and unsigned firmware go to Get Support Now Once signed firmware is installed subsequent firmware upgrades must be signed also There are no functional feature differences between signed and unsigned communication modules Communication between a redundant chassis pair that includes matching components makes redundancy possible Each chassis in the redundant chassis pair contains these ControlLogix components One ControlLogix power supply Required One ControlLogix redundancy module Required Redundancy modules link the redundant chassis pair to monitor events in each of chassis and initiate system responses as required At least one ControlLogix ControlNet or EtherNet IP communication module Required Up to two controllers Optional In addition redundant chassis are connected to other components outside the redundant chassis pair for example remote I O chas
159. d This diagram demonstrates how programs set to crossload and synchronize at varying intervals are executed after a switchover As is shown the new primary controller begins executing the program that follows the last crossload and synchronization point Figure 34 Program Execution After a Switchover no crossload after each program New Primary Controller Switchover Crossload For information about how to change the point in a task where a crossload occurs see Changing Crossload and Synchronization Settings on page 144 Rockwell Automation Publication 1756 UM535D EN P November 2012 Program the Redundant Controller Chapter 7 Multiple Periodic Tasks ATTENTION If you use multiple periodic tasks program all crucial outputs within the highest priority task Failure to program outputs in the highest priority task can result in outputs changing state if a switchover occurs In a project where multiple periodic tasks are used the point where program execution begins after a switchover depends on the following e Crossload and synchronization settings e Task priority settings As with the continuous task the controller begins executing at the program that follows the last crossload and synchronization point In addition a higher priority task may interrupt a lower priority task If a switchover occurs during or just after the higher priority task executes and the lower priority task has not been completed t
160. d to connect to HMI because your system requires that HMI be updated immediately after a switchover e PanelView Standard terminal PanelView 1000e or 1400e terminal For an unscheduled network lt 4 HMI terminals per controller are used For a scheduled network any amount of terminals within the limits of the ControlNet network are used PanelView Plus terminal VersaView industrial computer running a Windows CE operating system RSLinx Enterprise software version 5 0 or later is used Within each controller and communication module five connections for each PanelView Plus or VersaView terminal are reserved FactoryTalk View SE software with RSLinx communication software version 2 52 or later RSView 32 software RSLinx Enterprise software version 5 0 The number of RSLinx servers that a controller uses is limited to 1 4 maximum 1 Unscheduled ControlNet networks can be used however certain use considerations must be made See Chapter 5 Configure the ControlNet Network on page 93 EtherNet IP Module Checklist v Requirement EtherNet IP Module Identical EtherNet IP communication modules are placed in the same slot of both chassis of the redundant chassis pair EtherNet IP communication modules are one of these catalog numbers e 1756 EN2T 1756 EN2TXT 1756 EN2TR 1756 EN2F EtherNet IP Network With firmware revision 19 052 and later you can use an EtherNet IP network for 1 0 and produced consumed tag
161. dancy system 51 Recent Synchronization Attempts log 117 redundancy channels fiber optic cable 65 Rockwell Automation Publication 1756 UM535D EN P November 2012 redundancy firmware bundles bundles redundancy firmware 252 redundancy module 31 52 connect via fiber optic cable 63 date and time 115 info 111 112 install 57 lost connection between modules 222 status indicators 227 troubleshoot missing 223 Redundancy Module Configuration Tab qualification status 74 Redundancy Module Configuration Tool 49 105 additional configuration 106 check qualification 194 Configuration tab 113 115 Event Log tab 120 129 identify version 109 install 54 Module Info tab 111 112 open 107 Synchronization Status tab 119 Synchronization tab 116 119 System Event History tab 136 System Update tab 130 135 update 110 upgrade 252 redundancy modules replace 20 264 redundancy object attributes for crossload time 150 redundancy system update RSU 250 redundant chassis 24 designate 71 example 26 27 redundant fiber cable 64 redundant fiber ports single point of failure 16 redundant media ControlNet 41 redundant module qualify 74 remove 75 replace 75 reset 75 REM mode switch 68 remote 1715 Redundant 1 0 systems 35 44 communication modules 43 1 0 16 ControlNet 18 EtherNet IP 18 35 placement 44 Index remote controller unicast 84 remove redundant module 75 replace redundancy modules 20 264 redundant module 75 replace commu
162. dant Chassis on page 32 Install a Controller Use the installation information in the ControlLogix System User Manual publication 1756 UMO001 to complete the following for your controller e Installation in an enhanced redundancy system e Determination of compatibility for planned primary and secondary controllers in the redundant chassis see Table 6 on page 30 IMPORTANT The ControlLogix XT controllers function in the same way as the traditional controllers The ControlLogix XT products include control and communication system components that are conformally coated for extended protection in harsh corrosive environments e When used with FLEX I 0 XT products the ControlLogix XT system can withstand temperature ranges from 20 70 C 4 158 F e When used independently the ControlLogix XT system can withstand temperature ranges from 25 70 C 13 158 F For more information on using controllers in an enhanced redundancy system see Controllers in Redundant Chassis on page 29 Rockwell Automation Publication 1756 UM535D EN P November 2012 Install the Enhanced Redundancy System Chapter 3 Install the Redundancy Module You must install one redundancy module in each chassis planned for your system Available modules are as follows 1756 RM2 A 1756 RM2XT 1756 RM A 1756 RM B 1756 RMXT IMPORTANT Do not connect the primary redundancy module to the secondary redundancy module until al
163. date or locked switchover cannot be performed if the mode switch on either controller is not in the REM position Incompatible application A lock for update cannot be performed if the project names or applications are not identical in the primary and secondary chassis Initial secondary PTP time synchronization failure When PTP is enabled on the primary partner the secondary partner must be PTP time synchronized as well or it will not synchronize The initial secondary PTP synchronization attempt may fail before the automatic retry is successful In this case the event reports that initial failed attempt Invalid application A lock for update cannot be performed if test edits or SFC forces exist in the application Module insertion The 1756 RM 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 Module rejected lock for update command from 1756 RM module A module with a slot number specified in byte 0 of the extended status rejected the lock for update command See events from that module to determine the cause Module removal The 1756 RM 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
164. date status dialog box indicates completion Status 248 Rockwell Automation Publication 1756 UM535D EN P November 2012 ee 28 29 30 31 32 r Redundancy Commands Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C After the update completes reconnect the Ethernet cable or cables to the secondary Ethernet module and wait for communication to resume on the network Repeat steps 23 28 for all Ethernet modules that have their rotary switches set between 2 254 In RSLinx Classic software browse to the primary 1756 RM module Right click to select Module Configuration to open the RMCT Click the Synchronization tab in the RMCT Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History Become Primary Initiate Synchronize Secondary Disquelity Secondary 33 34 35 36 37 m Recent Synchronization Attempts Order Result Cause N Success N 1 Success N 2 Success N 3 Synchronization not attempted Refresh Description Select an entry in the Recent Synchronization Attempt list to see Details Click Synchronize Secondary then click Yes After the redundant chassis pair synchronizes select Initiate Switchover from the Synchronization tab in the RMCT then click Yes Module Info Configuration Synchronization Synchroniz
165. disconnect any communication cables while completing these steps e Completing a locked switchover causes SFC instructions to be reset to their initial state This may result in SFC instructions executing twice 1 Open the RMCT for the redundancy module in the primary chassis by right clicking on the RM module in RSLinx Classic software and selecting Module Configuration Backplane 1756 A44 4 00 1756 L73 LOGIXS573 Redundancy_update 02 1756 EN2T 1756 EN2T 4 amp 03 1756 RM2 A 1756 RM2 REDUNDANCY MODULE f 192 168 1 42 1756 EN2T 1756 EN2T A Remove Keer pang lillies ain Driver Diagnostics 00 1756 L73 LOGIX5573 Redundancy_update Configure Driver i oe 1756 EN2T 1756 EN2T A Upload EDS file from device Security Device Properties Module Configuration 2 Click the System Update tab Module Info Configuration Synchronization Synchronization Status Event LogC System Update Rystem Event History m System Update Commands Lock For Update Abort system Lock Initiate Locked Switchover 260 3 Click Lock For Update then click Yes 4 Wait for the system to lock Rockwell Automation Publication 1756 UM535D EN P November 2012 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C The System Update Lock Attempts log indicates when the system lock is complete System Update Lock Attempts System Lock
166. dless of the program s Synchronize Data after Execution setting To change the synchronization setting of a program open the program s Program Properties dialog box and check or uncheck Synchronize Data after Execution Program Properties MainProgram l i 2 joj x General Configuration Monitor Assigned Routines Main RSS Fault knone gt Inhibit Program v Synchronize Redundancy Data after Execution Concor Help 144 Rockwell Automation Publication 1756 UM535D EN P November 2012 Program the Redundant Controller Chapter 7 Default Crossload and Synchronization Settings The default setting for a program in a redundant project is for a crossload to occur at the end of each program execution However for an equipment phase the default is that the crossload not execute at the end of the phase Before you change the default crossload and synchronization settings read the sections that follow so you have a complete understanding of the implications For information about how to change the point in a task where a crossload occurs see Changing Crossload and Synchronization Settings on page 144 Recommended Task Types To avoid anomalies after a switchover occurs we recommend that you use only one of these task configurations when programming your redundant controllers Use either of the following e One continuous task e Multiple periodic tasks with one task at the hig
167. dundancy system to a new revision e During the upgrade procedures you cannot use RSLogix 5000 software to change the mode of the controller Instead use the mode switch on the front of the controller e Leave RSNetWorx for ControlNet software closed or offline throughout this procedure If the software is open or online you see errors in the RSNetWorx for ControlNet software during the upgrade process e Remember the following when completing the tasks described in the rest of this section Do not make any changes to the RSLogix 5000 project other than those identified in these tasks Verify that no one will be or is making changes to the project Do not use a FactoryTalk Batch Server to change equipment phase states when upgrading your enhanced redundancy system Step 2 Upgrade the Workstation Software Before you download and upgrade software for your redundant system use one of these methods to fully shut down RSLinx Classic software e Right click the RSLinx Classic icon in the notification area of the screen and choose Shutdown RSLinx Classic Restore F fa pE ei Shutdown RSLinx Classic TSUN Oom X ne 11 02 AM e With RSLinx Classic software open from the File menu choose Exit and Shutdown RSLinx Classic Gateway RSWho File Edit View Communications St Open Project Ctrl O Select Default Project Install the software required for your redundant system configuration S
168. dundancy Modules Chapter 6 Module Info Tab The Module Info tab of the RMCT provides a general overview of the redundancy module s identification and status information This status information is updated approximately once every two seconds Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History r Redundancy Module Identification Status Vendor Rockwell Automation Allen General State pi Bradley Major Fault None Product Type Redundancy Product Minor Fault None Error Code Product Code 3 Error Message Revision 20 4 4 Recovery Message Fiber Channel Switchover Counters Serial Number OOSS6DA6 Total 5 Product Name 1756 RM2 REDUNDANCY Periodic 0 MODULE Max Periodico 1 10 2 2012 15 20 50 659 Reset User Defined Identity Description Location Chassis B Primary with Synchronized Secondary CH1 Status Active CH2 Status Redundant Auto Synchronization State Aways Chassis Platform Configuration Enhanced NOTE Not all indicators are shown for 1756 RM A and 1756 RM B modules Rockwell Automation Publication 1756 UM535D EN P November 2012 111 Configure the Redundancy Modules These parameters are indicated in the Module Info tab Table 17 Module Info Tab Parameters Indicated Parameter Description Vendor Name of the redundancy module s vendor Product Type General pr
169. e L a a x ee t Dtiine D ERUN rey No Forces gt OK i No Edits ae ae Storage Redundancy 9 Controller Properties 10 Click Controller Properties 258 Rockwell Automation Publication 1756 UM535D EN P November 2012 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C 11 Click Change Controller fi Controller Properties Enhanced_Redundancy File Redundancy Nonvolatile Memory Memoy Security General MajorFaults MinorFauts Date Time Advanced SFC Execution Vendor Allen Bradley Type 1756 L75 ControlLogix5575 Controller Change Controller Revision 20 11 12 Specify the controller revision to which you are upgrading 13 Ifyou installed a new controller while upgrading the primary chassis firmware specify the new controller catalog number 14 Click OK 15 Access the Module Properties for each communication module in the chassis and specify the module firmware revision to which you are upgrading General Connection Time Sync Module Info Internet Protocol Port Configuration RSNetWore Type 1756 EN2T 1756 10 100 Mbps Ethemet Bridge Twisted Pair Media Vendor Allen Bradley Parent Local Name JENET_mod Description a Ethernet Address Private Network 192 1681 4 IP Address 3 z Chonn SC Revision 3 X 4 Electronic Keying Electronic Keying Compatible Module X R
170. e Cl z 9937 er 9 NR 44 47 777 2 176R FNIT__ IAM Transition Ta Nualihinn Serondan State CL lt gt Rockwell Automation Publication 1756 UM535D EN P November 2012 209 Chapter 9 The Description provides more information about the state change that p Event Details occurred No recovery method is described This p indicates that action is not required in response to this event 210 Troubleshoot a Redundant System TIP You can also use the Log Time column to identify a significant event Scan within a time range that corresponds to the time an event was reported or annunciated In addition you can also attempt to identify events by finding differences between times logged Such gaps in time often identify events that require troubleshooting When troubleshooting by identifying gaps in the time entries remember that gaps in months days or minutes may indicate a significant change to the system Not all events logged are indicative of an anomaly that needs to be corrected For example events classified as Minor Faults do not warrant corrective behavior unless they occur just before a switchover major fault or state change and can be identified as contributing to successive events 7 After you have located an event entry related to the anomaly you are troubleshooting double click the event to view Extended Event Information Chassis B Event Log Time S Module Description Classification 1
171. e ControlNet Network Topic Page Produce Consume Connections 93 Network Update Time 95 Use a Scheduled or Unscheduled Network 97 Schedule a New Network 98 Update an Existing Scheduled Network 100 Check the Network Keeper States 101 Produce Consume You can use produce consume connections over a ControlNet network Connections Controllers let you produce broadcast and consume receive system shared tags Figure 27 Example System Using Produced and Consumed Tags Primary chassis Secondary Chassis cee SST omron Se E Q tama iE 1756 EN2TR 1756 EN2TR Controller 1 Produced Tag Alien Bradley mare 33 Controller 2 Consumed Tag 1756 CN2R 1756 EN2TR 1756 CN2R Rockwell Automation Publication 1756 UM535D EN P November 2012 93 Chapter5 Configure the ControlNet Network Keep these points in mind when you use produced and consumed connections over a ControlNet network in an enhanced redundancy system e During a switchover the connection for tags that are consumed from a redundant controller can drop briefly The data does not update The logic acts on the last data that it received After the switchover the connection is reestablished and the data begins to update again e You cannot bridge produced and consumed tags over two networks For two controllers to share produced or consumed tags both must be attached to the same netw
172. e beyond the maximum permissible exposure recommendations Media redundancy is achieved by installing modules with redundant ports and installing a redundant fiber cable system If a cable failure occurs or cable is degraded the system uses the redundant network When using a redundant system route the two trunk cables A and B so that damage to one cable will not damage the other cable This reduces both cables being damaged at the same time Redundant cabling can tolerate one or more faults on a single channel If a fault were to occur on both channels the network operation would be unpredictable Rockwell Automation Publication 1756 UM535D EN P November 2012 Install the Enhanced Redundancy System Chapter 3 Connect the Fiber optic Communication Cable to Redundant Channels Follow this procedure to install the communication cable to redundant channels for the 1756 RM2 A module IMPORTANT The redundancy module communication cable contains optical fibers Avoid making sharp bends in the cable Install the cable in a location where it will not be cut run over abraded or otherwise damaged 1 Remove the black protective plug on the first redundancy module in the redundant chassis pair 2 Remove the protective caps from the cable 3 Plug the cable connectors into the first redundancy module The ends must be inserted opposite each other 4 Ifredundant fiber crossload cable is required install the second fiber cable
173. e communication with I O modules produced tags and consumed tags e Removing a ControlNet module from the redundant chassis can result in lost communication with I O modules produced tags and consumed tags e Ifthe entire system loses power you can be required to cycle power to the primary chassis to restore communication Set Partnered ControlNet Module Switches to the Same Address Where ControlNet modules are used as partners in a redundant chassis pair you must set the node address switches to the same node address The primary ControlNet modules can be at even or odd node addresses For example if partnered ControlNet modules are assigned to nodes 12 and 13 of the ControlNet network set the node address switches of the modules to the same address of 12 Figure 6 Example of Switch Address for Partnered ControlNet Modules 23 2 3 N z JN z ga 2819 ControlNet Module Switches tom A em Wis tom _ minir moo EZ O mae J m mi m Pira mF an mf ECI SES I l T ly Z fl Ly N oO oc EHS LO HHS HHHH S gt N HHS o zZ 4 md ji l Lu oO lu oO Oo i 1 co i 1 Te LO co Lo E N LO LO ire Lo lt N S L R E E q E cY
174. e describes the two to four character word abbreviations Table 47 Major Fault Code Messages 1st Word 2ndWord 3rdWord 4thWord Error Description CFG LOG ERR Configuration log error No action is required COMM RSRC ERR Communication resource error Reset the redundancy module COMM RSRC ERR PRT1 Port Communication resource error on Backplane Reset the redundancy module and check the chassis COMM RSRC ERR PRT2 Port2 Communication resource error on redundancy link Complete these tasks 1 Reset the module 2 Check the cable COMM ERR PRT1 Port Communication error Backplane communication Check or replace the chassis COMM ERR PRT2 Port2 Communication error on the redundancy link Check or replace the single mode cable COMM ERR General Communication Error No action is required DUPL RM Duplicate redundancy module This module is not in control Remove this redundancy module EVNT LOG ERR Event Log Error No action is required FMWR ERR Firmware error Update the firmware HDW ERR Hardware failure Replace the module 0s ERR Operating system error Replace the module RM PWR DOWN The redundancy module Power Down Module detected a DC_Fail condition Check the other modules in the chassis WDOG ERR Watchdog time out Reset the module WDOG FAIL Watchdog task failed its status check Replace the module Rockwell Automation Publication 1756 UM535D EN P N
175. e performed online while the redundant chassis pair is running synchronized To aid online repairs the fiber cable connections and SFP transceiver can be removed and inserted under power It is not mandatory to have the REDUNDANT channel connected between the two redundancy modules The redundant chassis pair can be synchronized with just one of the channels connected The REDUNDANT channel can be installed later while the chassis is running synchronized The status indicators on the front panel and the indicators and counters displayed in the RMCT provide monitoring of the channel status Rockwell Automation Publication 1756 UM535D EN P November 2012 139 Chapter6 Configure the Redundancy Modules Notes 140 Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Redundant Controller Program the Redundant Controller Topic Page Configure the Redundant Controller 141 Crossloads Synchronization and Switchovers 144 Crossloads and Scan Time 149 Program to Minimize Scan Times 152 Program to Maintain Data Integrity 159 Program to Optimize Task Execution 163 Program to Obtain System Status 168 Program Logic to Run After a Switchover 170 Use Messages for Redundancy Commands 171 Set the Task Watchdog 175 Download the Project 177 Store a Redundancy Project to Nonvolatile Memory 178 Online Edits 182 Chapter 7 Both controllers in the ControlLogix enhanced redundancy
176. e slice setting is between 10 and up to 50 the time allocated for servicing communication is fixed at 1 ms and the continuous task time slice changes to produce the desired ratio e When the system overhead time slice is greater than 50 90 the time allocated to the continuous task is fixed at 1 ms and the time allocated to servicing communication changes to produce the desired ratio Table 28 Overhead Time Slice At this time slice The continuous tasks runs for And service communication occurs for as long as 10 9ms 1ms 20 4ms 1ms 25 3 ms 1ms 33 2 ms 1ms 50 1ms 1ms 66 1ms 2 ms 75 1ms 3 ms 80 1ms 4ms 90 1ms 9 ms Rockwell Automation Publication 1756 UM535D EN P November 2012 Program the Redundant Controller Chapter 7 System Overhead Time Slice Examples This diagram illustrates a system where the System Overhead Time Slice is set to 20 default With this percentage communication is serviced after every 4 ms of continuous task execution Communication is serviced for up to 1 ms before the continuous task is restarted Figure 48 System Overhead Time Slice Set to 20 Legend Task executes Task is interrupted suspended 1ms 1ms 1ms 1ms 1ms Service Communication B B w B 4ms 4ms 4ms 4ms 4ms This diagram illustrates a system where the System Overhead Time Slic is set to 33 With this percentage communication is serviced after every 2 ms of continuo
177. e update is complete the Update status dialog box indicates completion _ tras aptae be araea 7 Ifyou are replacing or upgrading your controller hardware remove the controller from the secondary chassis and replace it with the new controller Use this table to determine if your planned primary and secondary controllers can be used together in the redundant chassis Table 50 Controller Compatibility Primary Controller Compatible Secondary Controller 1756 L61 1756 L61 1756 L62 1756 L63 1756 L64 1756 L65 1756 L62 1756 L62 1756 L63 1756 L64 1756 L65 1756 L63 1756 L63 1756 L64 1756 L65 1756 L64 1756 L64 1756 L65 1756 L65 1756 L65 1756 L71 1756 L71 1756 L72 1756 L73 1756 L74 1756 L75 1756 L72 1756 L72 1756 L73 1756 L74 1756 L75 1756 L73 1756 L73 1756 L74 1756 L75 1756 L74 1756 L74 1756 L75 1756 L75 1756 L75 1 Inthe ControlLogix enhanced redundancy system revision 19 052 the ControlLogix 1756 L65 controller s performance differs from that of the ControlLogix 1756 L64 controller IMPORTANT Controller compatibility is the same for the XT controllers as the standard controllers Rockwell Automation Publication 1756 UM535D EN P November 2012 257 AppendixC Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System 8 Complete steps 2 7 for each module in the secondary chassis including a new controller if applicable IMPORTAN
178. ease revisions 16 057 16 056 16 053 and 16 050 and releases earlier than revision 16 comprise the standard platform Enhanced The redundant chassis is operating on an Enhanced platform Modules supported in redundancy release revision 16 054 and all releases of revision 16 080 and later comprise the enhanced platform Hybrid The redundant chassis contains a mix of modules belonging to standard and enhanced platforms All Hybrid platforms are an unsupported redundant system configuration The default configuration of the redundancy modules lets you synchronize your redundant chassis without additional configuration if you are using a basic redundant chassis pair However some applications and uses of the redundancy system can require additional configuration For example you must use the RMCT for additional configuration if you need to complete any of these tasks e Set the redundancy modules to a different time or date recommended e Program your controller to control the redundant system e Change the redundancy synchronization options of the redundant system e Change the synchronization states of your redundant chassis e Conducta test switchover e Complete a firmware update of a module in the redundant chassis while the system is online If you need to complete any of these tasks reference the sections that follow Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Redundancy Modu
179. eceding events that may indicate the cause of the switchover Chassis B Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History Auto Update Partner Log ON OFF OPEN CLOSE Chassis B DSwP and matching end date and end time in Log Time Slot Module Na Description Classific Chassis B This is the time the redundancy module experienced a disqualifying event or switchover p 9945 3 24 2012 08 53 44 795 1 1756 RM 2 C2 Bridge Connection Deleted Starts 3 24 2012 08 53 44 775 1 1756 AM 2 C2 Bridge Connection Deleted Starts 3 24 2012 0 44 755 1 1756 RM 2 C2 Bridge Connection Deleted Starts ADT ae 1756 AM 2 C2 Bridge Connection Deleted tarts E 3 6 1756 AM 2 C2 Bridge Connection Deleted Starts 3 24 2012 08 53 44 716 1756 AM 2 C2 Bridge Connection Deleted Starts 9938 3 24 2012 08 53 44 715 1756 AM 2 C2 Bridge Connection Deleted Starts BRERA 9937 3 24 2012 08 53 44 715 1756 EN2T F Partner Connection Closed Synchre 9936 3 24 2012 08 53 44 714 1756 AM2 45 SYS_FAIL_L Active Failure 9935 3 24 2012 08 53 44 713 1756 EN2T 1 Network Transition to Not Attached Synchre 9934 3 24 2012 08 44 48 952 1756 RM 2 1E Chassis Redundancy State changed to OSwP State Cl 9933 3 24 2012 08 44 48 815 1756 EN2T 31 Transition To Qualified Secondary State Cl 99372 3224701 NA AA 47 277 175R FN T AM Transitio
180. econdary Controller 1756 L61 1756 L61 1756 L62 1756 L63 1756 L64 1756 L65 1756 L62 1756 L62 1756 L63 1756 L64 1756 L65 1756 L63 1756 L63 1756 L64 1756 L65 1756 L64 1756 L64 1756 L65 1756 L65 1756 L65 1756 L71 1756 L71 1756 L72 1756 L73 1756 L74 1756 L75 1756 L72 1756 L72 1756 L73 1756 L74 1756 L75 1756 L73 1756 L73 1756 L74 1756 L75 1756 L74 1756 L74 1756 L75 1756 L75 1756 L75 Differences in controller types between chassis can exist only during the system upgrade process When you complete the system upgrade the controllers in the redundant chassis pair must match for the system to synchronize For more information on using RSU see Appendix C Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System on page 239 e Inan enhanced redundancy system revision 19 052 or later the 1756 L65 controller s performance differs from that of the 1756 L64 controller Some controller operations can take slightly longer for the 1756 L65 controller to complete For example in some applications the 1756 L65 controller can experience longer scan times than the 1756 L64 controller 30 Rockwell Automation Publication 1756 UM535D EN P November 2012 Design an Enhanced Redundancy System Chapter 2 Plan for Controller Connections Consider these conditions when planning controller connection use e 1756 L6x controllers provide 250 total connections e 1756 L7x controllers provide 500 t
181. ections that is the connection between the primary controller and the remote controller and the connection between the remote controller and the primary controller for Multicast However if the redundancy system is the producer it can be Unicast because that is configured in the remote controller which is allowed 84 Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the EtherNet IP Network Chapter 4 IMPORTANT __ If controllers in the redundant chassis pair produce tags over an EtherNet IP network that controllers in remote chassis consume the connection from the remote controller to the redundant controller can briefly drop during a switchover This anomaly occurs if the EtherNet IP communication modules in the remote chassis do not use specific firmware revisions For the latest firmware revisions by product go to GET SUPPORT NOW For more information on produced and consumed connections see Logix5000 Controllers Produced and Consumed Tags user manual publication 1756 PM011 IMPORTANT Sockets are supported in the 1756 EN2T 1756 EN2TR and 1756 EN2F modules firmware revision 5 008 or later For additional information see ENET AT002 IMPORTANT Unicast functionality in enhanced redundancy systems supports produced tags Unicast consumed tags are not supported Configure EtherNet IP Use these procedures to configure EtherNet IP communication modules used in Communication Modules ina lt oU7427 chassi
182. ed event indicates module removal MM wo ww w Last normal event logged Chassis A Log Time Module Description Dimmed secondary Anant 5 chassis log indicates 325970 9 25 2009 11 00 49 0 1756 RM2 1A Chassis Redundancy State changed to PwQ5 issue with redundancy 325969 9 25 2009 11 00 49 0 1756 CN 21 Equally Able To Control module 325968 9 25 2009 11 00 49 0 325967 9 25 2009 11 00 48 3 325966 9 25 2009 11 00 48 9 325965 9 25 2009 11 00 47 9 ANPAD A AIAPIAAAN ad ADAAN 1756 CN 14 Enter Qualification Phase 4 1756 RM2 2E Qualification Complete 1756 CN 13 Enter Qualification Phase 3 1756 CN 12 Enter Qualification Phase 2 sara Aani OE Innvaonnvnvaa N The Partner RM Screamed event is logged by the redundancy module just before it is disconnected Depending on cause of the missing module the Partner RM Screamed event may not be logged before the module is lost Rockwell Automation Publication 1756 UM535D EN P November 2012 223 Chapter 9 224 Troubleshoot a Redundant System You can also browse to the redundancy module in RSLinx Classic software to determine if it is connected to the network A red X over the redundancy module indicates the module is not in the chassis Figure 66 Missing Redundancy Module in RSLinx Classic Software I Backplane 1756 A4 A t 1 01 1756 173 LOGIX5563 GDPOD1_ALARMS 02 1756 CN2R 1756 CN2PyB 03 1756
183. ee Software Requirements on page 49 for software versions required for use with this enhanced redundancy system revision Use the installation instructions or release notes provided with each software version for installation procedures and requirements Rockwell Automation Publication 1756 UM535D EN P November 2012 251 AppendixC Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Step 3 Download and Install the Redundancy Firmware Bundle Download and install the redundancy firmware revision bundle from the Rockwell Automation Support website at www rockwellautomation com support Follow these steps Click the Downloads link on the Get Support Now menu Click Firmware Updates under Additional Resources Click Control Hardware Click the 1756 Lxx Enhanced Redundancy Bundle file aR YW N The Flash Firmware Updates window appears Enter your Serial Number Click Qualify For Update Click Finish when the Qualified For Update window appears Download the zipped file Wain awn Install the Redundancy Firmware Bundle Step 4 Upgrade the Redundancy Module Configuration Tool The RMCT version 8 01 05 is included in the enhanced redundancy system revision 20 054_kit1 bundle Once this bundle is installed you can use the RMCT version 8 01 05 Verify Your RMCT Version Complete these steps to check or verify the version of the RMCT you have installed 1 Launch RSLinx Clas
184. em is running online make these considerations e Do not use Rack Optimized communication formats The ControlNet module and I O must be configured for direct connections e For each remote I O module used plan for one direct connection to be used Complete these steps to schedule a new ControlNet network for an enhanced redundancy system 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 1756 CN2 B or 1756 CN2R B module may not match its partner and the secondary chassis will fail to synchronize 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 click OK Check Edits Enabled Nn TW eR YS N V Edits Enabled 7 From the Network menu choose Properties Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the ControlNet Network Chapter 5 8 In the Network Parameters tab enter the parameters that are appropriate for your system Network Parameters Media Configuration General Current Pending Network Update Time ms po oo Max Scheduled Address 20 ie Max Unscheduled Address 20 kpe Network Name _ default default Media Redundancy Parameter Speci
185. emory Security Redundancy Enabled daan aO Advanced Redundancy Configuration x gt Retain Test Edits on Switchover Memory Usage Indicate whether more of the processor memory thatis free after download is to be reserved for online creation of tags or logic Reserve more memory for online addition of Tags Logic cot e 184 Rockwell Automation Publication 1756 UM535D EN P November 2012 Program the Redundant Controller Chapter 7 IMPORTANT When using a 1756 L7x redundancy controller using version 19 software and the Memory Usage slider is set all the way to Tags the first synchronization attempt will be successful but after switchover or disqualification the next qualification attempt will fail and one or more entries will appear in the secondary redundancy module event log with the following description 14 Error Setting Up Data Tracking To recover from this issue move the slider slightly to the right This must be done offline or in Program mode Additionally you must download the updated application to the disqualified secondary to update its configuration The next qualification attempt is successful Advanced Redundancy Configuration x Memory Usage Indicate whether more of the processor memory that is free after download is to be reserved for online creation of tags or logic Reserve more memory for online addition of Tags Logic
186. ending on your redundant application you may need to change the memory usage property for your redundant controller The setting you specify impacts how the controller divides memory for tags and logic to be stored to the buffer during a crossload to the secondary controller IMPORTANT For most applications we recommend that the Memory Usage slider remain at its default position center This table indicates when you might need to change the memory usage setting Table 34 Possible Memory Usage Setting Change If your online edits are primarily changes to Then move the Memory Usage slider towards Tags with little or no changes to logic Tags Logic with little or no new tags created Logic IMPORTANT Donotsetthe Memory Usage slider all the way to Tags or Logic Ifyou move the slider all the way to Tags you may not be able to perform edits while online and OPC communication may fail Ifyou move the slider all the way to Logic you cannot create or edit any tags while online Rockwell Automation Publication 1756 UM535D EN P November 2012 187 Chapter7 Program the Redundant Controller Notes 188 Rockwell Automation Publication 1756 UM535D EN P November 2012 Tasks to Monitor the System Controller Logging Chapter 8 Monitor and Maintain an Enhanced Redundang System Topic Tasks to Monitor the System Page 189 Controller Logging 189 Use Programming to Monitor System Status 190 Veri
187. er 2 The use of redundant ControlNet media helps to prevent a loss of communication if a trunkline or tap is severed or disconnected A system that uses redundant ControlNet media uses these components e 1756 CN2R B communication modules in each redundant chassis e ControlNet modules designed for redundant media at each ControlNet node on the network e Redundant trunk cabling e Redundant tap connections for each ControlNet module connected Figure 8 Redundant ControlNet Media with Redundant ControlLogix Chassis Redundant ControlLogix Chassis with 1756 CN2R Modules IN Workstation with ControlNet Interface Card CUS Redundant Trunk Lines E 1785 L80C15 Rockwell Automation Publication 1756 UM535D EN P November 2012 41 Chapter2 Design an Enhanced Redundancy System Other Communication You can use only EtherNet IP and ControlNet networks and corresponding Networks modules in enhanced redundancy systems IMPORTANT Do not use the redundant chassis to bridge between networks Bridging through the redundant chassis to the same or different networks or routing messages through redundant chassis is not supported You can bridge to other communication networks outside of the redundant chassis For example you can bridge to a Universal Remote I O network via a remote chassis
188. erChassis INT GSV If Then chassis RedundancyState 16 8 Synchronized secondary 16 9 Disqualified secondary with primary 16 E No partner 16 12 Secondary locked for update Redundancy status of the controller ModuleRedundancy State INT GSV If Then 16 2 Primary with synchronized secondary 16 3 Primary with disqualified secondary 16 4 Primary with no secondary 16 6 Primary with synchronizing secondary 16 F Primary locking for update 16 10 Primary locked for update Redundancy state of the partner PartnerModule INT GSV If Then RedundancyState 16 7 Synchronizing secondary 16 8 Synchronized secondary 16 9 Disqualified secondary with primary 16 E No partner 16 11 Secondary locking for update 16 12 Secondary locked for update Results of the compatibility checks CompatibilityResults INT GSV If Then with the partner controller 0 Undetermined 1 No compatible partner 2 Fully compatible partner Rockwell Automation Publication 1756 UM535D EN P November 2012 273 AppendixE Redundancy Object Attributes For this information Get this attribute Data GSV SSV Description Type Status of the synchronization Qualification InProgress INT GSV If Then qualification process 1 Synchronization qualification
189. erprise software version 3 0 or later is used IP address swapping is used HMI and both redundant chassis are on the same subnet FactoryTalk View SE software with RSLinx software version 2 x RSView 32 software Any other HMI client software that uses RSLinx software version 2 x The number of RSLinx servers that a controller uses is limited to 1 4 maximum 1 Other IP address configurations are permitted but require additional considerations For more information see Use IP Address Swapping on page 77 Project and Programming Checklist In addition to the checklist below see the ControlLogix Controller Checklist on page 279 v Requirement The Redundancy Module Date and Time has been set by using the RMCT One project is created by using RSLogix 5000 software and is downloaded to the primary controller Redundancy is enabled within the Redundancy tab of the Controller Properties dialog box Task configuration is either e One continuous task within the project or e Multiple periodic tasks with only one task at the highest priority Also multiple tasks are structured so that the fewest possible separate tasks are used The redundant controller program does not contain e Event tasks e Inhibited tasks Programming specific to critical 1 0 that must be bumpless is placed in the highest priority user task according to your task configuration If you use this task structure Then programm
190. essages For certain faults the module status display provides recovery instructions Up to four four character words are displayed Table 49 Recover Messages Recovery Instruction Code Description RPLC MOD Replace the module RSET MOD Reset the module REMV MOD Remove the module SEAT MOD Reinsert the module into the chassis Rockwell Automation Publication 1756 UM535D EN P November 2012 235 AppendixA Status Indicators Notes 236 Rockwell Automation Publication 1756 UM535D EN P November 2012 Event Description Autoqualification trigger Appendix B Event Log Descriptions This table lists and explains some of the most commonly experienced event descriptions found in the Event Log of the RMCT Use this table as a reference when determining if an event on your system requires additional troubleshooting Description Something happened that caused the system to try and synchronize again Double click the event to see what happened Blank memories rule 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 wi
191. et IP communication modules Table 14 System Resource Utilization Table If the CPU utilization Then rate is 0 80 No action is required Important This is the optimal rate Greater than 80 Take steps to reduce your CPU utilization See the EtherNet IP Network Configuration user manual publication ENET UM001 Adjust your connection s requested packet interval RPI Reduce the number of devices connected to your module Important Your EtherNet IP communication module can function at 100 CPU capacity but at or near this rate you run the risk of CPU saturation and performance problems Use IP Address Swa pping IP address swapping is a feature available to EtherNet IP communication modules in an enhanced redundancy system where a partnered set of EtherNet IP communication modules swap IP addresses during a switchover IMPORTANT You must use IP address swapping to use remote 1 0 and produce consume connections of an EtherNet IP network Rockwell Automation Publication 1756 UM535D EN P November 2012 77 Chapter4 Configure the EtherNet IP Network Determine Use of IP Address Swapping Depending on your EtherNet IP network configuration you can choose to use IP address swapping between your partnered EtherNet IP communication modules in the event of a switchover If your partnered EtherNet IP communication modules are on Then the Same subnet use IP address swapping Different subnets do not use IP addre
192. formation see Redundant Chassis on page 28 Rockwell Automation Publication 1756 UM535D EN P November 2012 277 AppendixF Enhanced Redundancy System Checklists Remote 1 0 Checklist v Requirement 1 0 is not placed in redundant chassis 1 0 is connected to the redundant chassis by using one of these networking options ControlNet connections to the same ControlNet network as the redundant controller chassis without bridging EtherNet IP connections to the same EtherNet IP network as the redundant controller chassis without bridging If in the 1 0 tree of the redundancy controller all 1 0 and consumed tag connections must be multicast connections The 1 0 tree of the redundancy controller may contain produced unicast tags consumed by remote users e A DeviceNet network connected through a 1756 DNB DeviceNet communication module in a remote that is nonredundant chassis e A universal remote 1 0 or Data Highway Plus network connected through the use of a 1756 DHRIO module in a remote nonredundant chassis Redundancy Module Checklist v Requirement One redundancy module is placed in the same slot of each redundant chassis Series A and B redundancy modules are fully compatible Therefore you can use any combination of them in a partnered set for example a 1756 RM A module in the primary chassis and a 1756 RM B module in the secondary chassis However the best scan performance occurs when two Series B redundancy mod
193. fy Network Update Time ms The minimum repetitive interval when data is sent over the ControlNet network Max Scheduled Address The highest node number that uses scheduled communication on the network Max Unscheduled Address The highest node number that you use on the network Media Redundancy The ControlNet channels you are using Network Name Aname for identifying the ControlNet network 9 Click OK 10 From the Network menu choose Single Pass Browse 11 From the File menu choose Save 12 Type a name for the file that stores the network configuration then click Save 13 Click Optimize and re write Schedule for all Connections default and click OK Save Type Optimize and re write schedule for all connections Merge changes inte existing schedule You have finished scheduling your new ControlNet network Rockwell Automation Publication 1756 UM535D EN P November 2012 99 Chapter5 Configure the ControlNet Network Update an Existing Scheduled Network ControlNet network NW e YW N 9 10 11 12 13 100 Turn on the power to each chassis Start RSNetWorx for ControlNet software From the File menu choose Open If you are adding the redundant chassis to an existing ControlLogix system that uses a ControlNet network complete these steps to update the existing Select the file for the network and click Open From the Network menu choose Online Click Edits Enabled
194. fy Date and Time Settings 191 Verify System Qualification 192 Check the ControlNet Module Status maintain your enhanced redundancy system 197 This chapter describes some of the key tasks to complete to monitor and Beginning with enhanced redundancy system revision 19 052 you can use the controller logging feature This feature provides a way to detect and log changes that is RSLogix 5000 software and controller mode switch interactions made to ControlLogix 1756 L6x and 1756 L7x controllers without adding any auditing software With controller logging the controller can perform these tasks e Detect changes and create logs entries containing information about the changes e Store the log entries toa Compact FLASH CF card or Secure Digital SD card for later review Provide programmatic access to log entry counters to provide change detection information remotely Rockwell Automation Publication 1756 UM535D EN P November 2012 189 Chapter8 Monitor and Maintain an Enhanced Redundancy System Use Programming to Monitor System Status 190 Controller Log A controller log is the record of changes The log is stored on the controller s NVS memory automatically You can store the log to a CF card or SD card on an as needed basis or automatically at predefined times The controller s NVS memory and each external memory card type have a maximum number entries they can store Specif
195. hassis B Event Log Event Log Time 5 Module Description Classification 168170 9 25 2009 10 27 08 2 3 1756 RM2 C2 Bridge Connection Deleted Starts Stops 168169 9 25 2009 10 27 08 2 3 1756 RM2 C2 Bridge Connection Deleted Starts Stops 168168 9 25 2009 10 27 08 2 3 1756 RM2 C2 Bridge Connection Deleted Starts Stops 16816 9 25 2009 10 27 08 2 3 1756 RM 2 C2 Bridge Connection Deleted Starts Stops 168166 9 25 2009 10 27 08 2 3 1756 RM 2 C2 Bridge Connection Deleted Starts Staps A switchover is 168165 9 25 2009 10 27 08 1 3 1756 RM2 BD SYS_FAIL_L Active in Partner RM Failure initiated 168164 9 25 2009 10 27 08 1 1756 RM 2 30 Switchover Attempted Switchover 168163 9 25 2009 10 11 52 2 3 1756 RM 2 32 Autoqual State Change Configuration 168162 9 25 2009 10 11 52 2 3 1756 RM2 F Autoqual Option Setto Always Configuration 9 25 2009 10 11 38 9 3 1756 RM 2 1E Chassis Redundancy State changed State Changes Event indicates chassis state is as a qualified secondary 220 168160 9 25 2009 10 11 38 9 168159 9 25 2009 10 11 24 3 166158 9 25 2009 10 10 55 3 168157 9 25 2009 10 10 55 3 168156 9 25 2009 10 10 55 3 1756 CN 31 Transition To Qualified Secondary State Changes 1756 CN 30 Transition To Qualifying Secondary State Changes 1756 RM 2 91 Response to Open Bridge Connection Starts Stops 1756 CN 10 Partner Connection Opened Synchronization 1756 R
196. he cable lengths and the corresponding link penalties All penalties that affect the link performance must be accounted for within the link optical power budget Table 12 Optical Power Budget Ranges Transmitter Min Typical Max Unit Output optical power 15 8 dBm Wavelength 1261 1360 nm Receiver Min Typical Max Unit Receiver sensitivity 38 3 dBm avg Receiver overload 8 dbm avg Input operating wavelength 1261 1580 nm Step 4 Update Redundant Use ControlFLASH software to upgrade the firmware of each module in Chassis Firmware each chassis IMPORTANT Apply power ONLY to the chassis containing modules on which you are upgrading firmware Upgrade firmware on only one module at a time Rockwell Automation Publication 1756 UM535D EN P November 2012 67 Chapter3 Install the Enhanced Redundancy System IMPORTANT Redundancy module firmware contained in the enhanced redundancy system firmware bundle is designed for use with the 1756 RM 1756 RM2 A 1756 RMXT and 1756 RM2XT redundancy modules Upgrade the Firmware in the First Chassis Complete these steps to upgrade the firmware in the first chassis 1 Apply power to the chassis a SE Ee YW EN EN EN AAN NS Gels va om cI G Lo EE By 7 44490 2 Set the mode switch on the controller to REM JUVE a NI GZ
197. he new secondary chassis except for the redundancy module that was already upgraded as described in Step 7 Upgrade the Primary Chassis Redundancy Module Firmware on page 255 Rockwell Automation Publication 1756 UM535D EN P November 2012 261 AppendixC Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Primary Chassis Secondary Chassis 262 Ifyou are replacing and upgrading your controller hardware remove the controller from the secondary chassis and replace it with the new controller Launch ControlFLASH software and click Next Select the module catalog number and click Next Enter the catalog number of the target device fi 756 L75 1756 L635 1756 L64 1756 L65 1756 L71 1756 L72 1756 L73 1756 L74 1756 LSP 17REMNJAF 4 Browse to the module and select it A 192 168 1 41 1756 EN2T 1756 EN2T A _ _ Pr H 192 168 1 42 1756 EN2T 1756 EN2T 4 amp Backplane 1756 44 4 S M00 1756 L75 LOGIX5575 1756 L75 A LOGIX5575 01 1756 RM 1756 RM B REDUNDANCY MODUL 02 1756 EN2T 1756 EN2T A 5 Click OK 6 Select the firmware revision to upgrade to and click Next 7 Click Finish The firmware begins to update When the updated is complete the Update status dialog box indicates completion a tma pra bee sen 8 Complete steps 2 Z for each module in the new secondary chassis including the new cont
198. he qualification status of the modules displayed on the module status display Table 13 Qualification Status Interpretation Module Status Display Interpretation QFNG Qualification processes are in progress SYNC SYNC displays after qualification processes are complete This indicates that chassis configuration and the firmware revision levels are compatible and that the secondary chassis is ready to assume control in the event of a major fault in the primary chassis DISQ QFNG DISQ If DISQ continues to display after about three minutes one of these anomalies exists e Incorrect chassis configuration That is incompatible hardware is used Incompatible firmware revisions are used between the primary and secondary modules e Keeper parameters between ControlNet module partners are not the same e The partnered ControlNet modules are not set to the same node address The Auto Sychronization parameter within the Redundancy Module Configuration Tool is set to Never Conversion from a Nonredundant to a Redundant System You can upgrade the standalone chassis to a redundant chassis pair by inserting a redundancy module in the standalone chassis and setting up an identical chassis with compatible modules including the redundancy module in the same slot as the standalone chassis If the partnered chassis containing nonredundant modules or nonredundancy compliant firmware is designated as the secondary chassis i
199. he redundant chassis pair are connected and powered they determine which chassis is the primary chassis and which is the secondary chassis The redundancy modules in both the primary and secondary chassis monitor events that occur in each of the redundant chassis If certain faults occur in the primary chassis the redundancy modules execute a switchover to the unfaulted secondary chassis System Qualification and Synchronization When the enhanced redundant system is first started the redundancy modules run checks on the redundant chassis to determine if the chassis contain the appropriate modules and firmware to establish a redundant system This stage of checks is referred to as qualification After the redundancy modules complete qualification synchronization can take place Synchronization is a state in which the redundancy modules execute these tasks e Verify that the connection between redundancy modules is ready to facilitate a switchover e Verify that the redundant chassis continue to meet qualification requirements e Synchronize the data between the redundant controllers also called crossloading This data is crossloaded Updated tag values Force values Online edits Other project information Synchronization always takes place immediately following qualification Also depending on your system configuration synchronization can take place at the end of each program run within the controller project or at othe
200. header for remote 1 0 module placement Added HMI Blind Time reduction on an EtherNet IP network during a switchover Added information about enhanced communication modules and unicast connections Added restrictions when using firmware revision 19 052 versus 19 053 Added the 1756 L71 1756 L73XT controllers 1756 EN2F module and 1756 A7XT chassis to the table of components available for use in a redundant chassis pair Listed power supplies available for a redundant chassis pair Corrected revision 19 052 to 19 053 Added or later to revision 19 052 here and throughout the manual Added or later to revision 19 052 here and throughout the manual and chassis size to configuration requirements Added 1756 L71 controller for controller compatibility and updated revision information Rearranged EtherNet IP and ControlNet networks sections added 1756 EN2F module information Added remote chassis access restrictions using an EtherNet IP network added or later to revision 19 052 Added unicast functionality Added information about using a remote chassis access using a ControlNet network Added additional information about 1715 Redundant 1 0 Systems Rockwell Automation Publication 1756 UM535D EN P November 2012 283 Appendix G 284 Enhanced Redundancy Revision History Publication Revision and Date Topic Added firmware requirements for revisions 20 054 and 19 05
201. hen the lower priority task and programs are executed from the point at which the last crossload occurred This diagram demonstrates how tasks at different priorities execute if a switchover occurs while a lower priority task is executing Note that the crossload and synchronization points in this example are set to occur only at the end of the last program within the tasks and not at each program s end Figure 35 Normal Periodic Task Execution no switchover Crossload Crossload Task Priority 1 Task Priority 1 Program 1 Program 2 Program 3 l Program 1 Program 2 Program 3 Task Priority 2 ma ESSERE jj Higher priority Lower priority Crossload Task Interupts Task Resumes Task Priority 2 Program 1 Progr Rockwell Automation Publication 1756 UM535D EN P November 2012 147 Chapter7 Program the Redundant Controller The diagram below shows a lower priority task that has not been completed and a switchover occurs The lower priority task and programs are executed from the beginning of the program where the switchover occurred This is because the program uses the default configuration and crossloads and synchronization points occur at the end of each program Figure 36 Periodic Task Execution After Switchover When Configured to Crossload After Programs Task Priority 1 eae oven Task Priority 2 Pa Crossload Program 2_ Programs SS E E Crossload
202. hest priority The sections that follow explain the impact of crossloads and synchronization after a switchover based on the task structure you use Continuous Task After Switchover After a switchover occurs within a controller project that contains only a continuous task the new primary begins executing at the last crossload and synchronization point Depending on your crossload and synchronization setting the program that the new primary controller begins with may be the following e The program that was interrupted by the switchover e The program that immediately follows the last crossload and synchronization point Rockwell Automation Publication 1756 UM535D EN P November 2012 145 Chapter 7 146 Program the Redundant Controller Primary Controller Crossload Continuous Task with Crossloads at Each Program End This diagram demonstrates how programs set to crossload and synchronize at each program end are executed after a switchover As is shown the new primary controller begins executing at the beginning of the program that was interrupted by the switchover This is the switchover execution that occurs if you use the default crossload and synchronization setting for a program Figure 33 Program Execution After a Switchover crossload after each program New Primary Controller rene Switchover Primary Controller a Crossload Crossload Crossload Continuous Task with Varying Crossloads at Program En
203. his information Get this attribute Data GSV SSV Description Type In a pair of redundant chassis PhysicalChassisID INT GSV If Then identification of a specific chassis without regard to the state of the 0 Unknown chassis 1 Chassis A 2 Chassis B Slot number of the 1756 RM module 1756 RM SlotNumber INT GSV in this chassis Size of the last crossload LastDataTransfer Size DINT GSV This attribute gives the size of data that was or would have been crossloaded in the Size of the last crossload if you last scan in the number of DINT s 4 byte words had a secondary chassis The secondary chassis does not have to be connected or online If you do not have a secondary chassis the number of DINT s that would have been crossloaded are indicated Size of the biggest crossload MaxDataTransfer Size DINT GSV This attribute gives the biggest size of the LastDataTransfer Size attribute in DINTs Size of the biggest crossload if you SSV 4 byte words had a secondary chassis The secondary chassis does not have to be connected or online If you do not have a secondary chassis the largest number of DINTs that would have been crossloaded are indicated If you need to reset this value use an SSV instruction with a Source value of 0 Rockwell Automation Publication 1756 UM535D EN P November 2012 275 AppendixE Redundancy Object Attributes Notes 276 Rockwell Automation Publication 1756 UM535D EN P November 2012 Appendix
204. ible The SysFail test was unsuccessful in the primary redundancy module A Major Recoverable Fault occurred in primary redundancy module A Major NonRecoverable Fault occurred in primary redundancy module A module was inserted into the chassis A module was removed from the chassis A failed module exists in the secondary chassis A failed module exists in the primary chassis An Abort System Update command received Invalid response was received from a module A module rejected the state change A platform mismatch was detected 134 Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Redundancy Modules Chapter 6 Locked Switchover Attempts The Locked Switchover Attempts log provides information about the status of the last four locked switchover attempts This log includes this information about each attempt e Time and date e Status e Result The status indicated in the Locked Switchover Attempts log can be any one of the states listed in this table Table 23 Locked Switchover Event Log Statuses Status Description Not Attempted A locked switchover has not been attempted since the last powerup In Progress A locked switchover is currently in progress Success A locked switchover was successfully completed Abort The locked switchover attempt failed The cause of the failure is indicated in a Result field Ifa locked switchover is aborted it can be because of the following
205. ic events are stored in the controller s log For more information on controller logging see Logix5000 Controllers Information and Status Programming Manual publication 1756 PM015 Controller Logging in Enhanced Redundancy Systems Because enhanced redundancy systems operate with partnered controllers there are considerations you must consider with regard to controller logging e The primary and secondary controllers maintain separate logs e You do not need to synchronize the logs e On the primary controller controller logging occurs exactly as it does on a controller in a nonredundant system regardless of whether the system is qualified and synchronized or disqualified e A secondary controller logs the removal or insertion of removable storage components that is a CF or SD card in any operating state Otherwise the secondary controller only logs events that occur when the controller is in a disqualified state IMPORTANT When programming your enhanced redundancy system program so your redundancy system status is continually monitored and displayed on your HMI device If your redundancy system becomes disqualified or a switchover occurs the change in status is not automatically annunciated You must program the system to communicate the change in status via your HMI or other status monitoring device For more information and programming techniques see Program to Obtain System Status on page 168 Rockwell Autom
206. ication path to the partner or secondary module and click OK The Export Diagnostics dialog box will appear and prompt you to specify a location to save the export file Export Diagnostics File name ced Output 57F245_chassis_A B 05172012_1051 dbg Browse Cancel Rockwell Automation Publication 1756 UM535D EN P November 2012 215 Chapter9 Troubleshoot a Redundant System Keeper Status Causing Synchronize Failure 216 5 Name and save the export file 6 Click Export It may take several minutes to export all of the data The Export Diagnostic Complete dialog box appears once the export has completed Export Diagnostic Diagnostic data export is completed 7 Click OK Forward this diagnostics file to Rockwell Automation Technical Support only if requested to do so Contact Rockwell Automation Technical Support If you tried to use the event logs to troubleshoot your redundant system and are unsuccessful prepare to contact Rockwell Automation s Technical Support by exporting the event logs of both the primary and secondary redundancy modules The technical support representative who assists you will use those files to help determine the cause of a switchover or other anomaly For more information about exporting the event logs see Export Event Log Data on page 124 To determine if a keeper status anomaly is causing a synchronization failure you can view the module status display of the ControlNet
207. icator Indicator State Off Description No power is applied to the redundancy module If necessary apply power Solid red One of these conditions exists e The redundancy module is conducting a self test during powerup No action necessary The redundancy module has experienced a major shutdown fault Cycle power to clear the fault If the major fault does not clear replace the module Flashing red One of these conditions exists e The redundancy module is updating its firmware No action necessary e The redundancy module has been configured improperly Check the module configuration and correct any issues The redundancy module has experienced a major fault that may be cleared remotely using the RMCT Solid green The redundancy module is operating normally No action required Flashing green The redundancy module is operating normally but is not communicating with the other redundancy modules in the same chassis If necessary establish communication with the other redundancy module CH1 and CH2 Status Indicators The CH1 and CH2 status indicators reveal the following module states Table 42 CH1 and CH2 Status Indicators Indicator State Off Description One of these conditions exists No power e RM major fault NVS update Solid red One of these conditions exists No transceiver plugged in e Faulted or failed transceiver detected e Transceiver with
208. incorrect or vendor ID detected Intermittent red For 1 s then off indicates powerup Flashing red One of these conditions exists e Redundant channel error e No cable connection Intermittent green On for 256 ms for each packet received then off Active operating channel Channel used for data communication between the partner 1756 RM2 A modules Flashing green Indicates that this channel is operating as the back up channel and is ready to become the Active channel if the current Active channel fails Unknown Operating state is not yet determined Active Channel is operating normally as the active channel Rockwell Automation Publication 1756 UM535D EN P November 2012 229 AppendixA Status Indicators Indicator State Redundant Description Channel is operating normally as the redundant channel Link Down Channel is disconnected Several causes could be The cable is disconnected broken or damaged The signal is attenuated The connector is loose The partner 1756 RM2 module is powered down or in a major fault state No SFP No transceiver was detected Several causes could be Ithas failed Itis loosely connected Itis not installed SFP Cpt The transceiver is not supported by Rockwell Automation SFP Fail The transceiver is in a failed state 1 May be present for either CH1 or CH2 but not both at the same time
209. ing specific to bumpless 1 0 is in One continuous task The continuous task One continuous task and one or more periodic tasks The highest priority periodic task where only that one task is at the highest priority Multiple periodic tasks The highest priority periodic task where only that one task is at the highest priority For 1756 L6x controllers the task watchdog is 2 maximum_scan_time 150 ms when using ControlNet 1 0 and 2 maximum_scan_time 100 ms when using Ethernet 1 0 where maximum_scan_time is the maximum scan time for the entire task to complete when the redundant controllers are synchronized To calculate watchdog time for 1756 L7x controllers see Minimum Value for the Watchdog Time on page 177 Rockwell Automation Publication 1756 UM535D EN P November 2012 281 Appendix F Enhanced Redundancy System Checklists v Requirement Scan time is minimized by using these techniques when possible e Unused tags are eliminated Arrays and user defined data types are used instead of individual tags e Redundancy data is synchronized at strategic points by using the Synchronize Data after Execution setting in the Program Properties dialog box Programming is written as compactly and efficiently as possible Programs are executed only when necessary Data is grouped according to frequency of use DINT tags are used instead of SINT or INT tags For produced consumed data the co
210. inish No action is required 222 Resolving initial redundancy module state Wait for state resolution to finish No action is required PRIM Primary redundancy module The module is operating as the primary module No action required DISQ Disqualified secondary redundancy module Check the secondary partner module s type and revision QFNG Qualifying secondary redundancy module Redundant system status No action is required SYNC Qualified secondary redundancy module Redundant system status No action is required LKNG Secondary redundancy module that is in process of locking for update LOCK Secondary redundancy module that is locked for update Exxx Major fault has occurred xxx represents an error or fault code with the two least significant characters in decimal Use the Error ID code to diagnose and address the error For more information on error codes see Redundancy Module Fault Codes and Display Messages on page 233 EEPROM Update Required On board EEPROM is empty Replace the module BOOT Erase Error Error in erasing NVS device while updating boot image Cycle power to the module If the error persists replace the module BOOT Program Error Error in writing in NVS device while updating boot image Cycle power to the module If the error persists replace the module APP Erase Error Error in erasing NVS device while updating application image Cycle power to the redundancy module If the error persists replace the module APP Prog
211. ion and memory size Within each redundant chassis one or two maximum of these controllers are used e 1756 L61 1756 L62 1756 L63 1756 L63XT 1756 L64 1756 L65 e 1756 L71 1756 L72 1756 L73 1756 L73XT 1756 L74 1756 L75 Do not combine 1756 L6x and 1756 L7x controllers in a redundant chassis Each controller in the redundancy chassis has enough memory to store twice the amount of controller data and 1 0 memory See Knowledgebase ID 28972 for more information Eight controller connections are reserved for redundancy use 1 When using ControlLogix enhanced redundancy system revision 16 081 or earlier you cannot use two 1756 L64 controllers in the same chassis You can however use a 1756 L64 controller in the same chassis as a 1756 L61 1756 L62 or 1756 L63 controller ControlNet Checklist v Requirement ControlNet Module Identical ControlNet modules are placed in the same slot of both chassis of the redundant pair ControlNet modules are identical in redundancy firmware revision and in series Only the 1756 CN2 B 1756 CN2R B or 1756 CN2RXT ControlNet modules are used Partnered ControlNet modules both have identical keeper information as explained in the ControlNet Modules in Logix5000 Control Systems User Manual publication CNET UM001 Three connections of the ControlNet module are appropriately reserved for redundancy system use ControlNet Network USB ports of communic
212. ion 1756 UM535D EN P November 2012 11 Table of Contents Notes 12 Rockwell Automation Publication 1756 UM535D EN P November 2012 Preface This publication provides this information specific to enhanced redundancy systems e Design and planning considerations e Installation procedures e Configuration procedures e Maintenance and troubleshooting methods This publication is designed for use by anyone responsible for planning and implementing a ControlLogix enhanced redundancy system e Application engineers e Control engineers e Instrumentation technicians The contents of this publication are for those who already have an understanding of Logix5000 control systems programming techniques and communication networks IMPORTANT The 1756 RM2 A and 1756 RM2XT modules are interference free with regard to safety functions and can be used in ControlLogix SIL2 applications Additional Resources These documents contain additional information concerning related products from Rockwell Automation Table 2 Additional Documentation Resource Description 1756 ControlLogix Controllers Specifications Technical Data publication 1756 TD001 Contains specifications on ControlLogix controllers and redundancy modules 1715 Redundant 1 0 Specifications publication 1715 TD001 Contains specifications on a Redundant 1 0 system 1715 Redundant 1 0 System User Manual publication 1715 UM001 Contains information on how to in
213. ion Cancel 4 To change the file name or save location to something other than the default select the Browse button 5 Click Export 6 Select the 1756 RM in the secondary chassis In the following example chassis A is the secondary chassis Autobrowse 0 Browsing node 3 found Workstation USMAYSAMILLSO3 5 Linx Gateways Ethernet E Ja 1784 PCIDS 1 DeviceNet AB_ETHIP 1 Ethernet E f 10 88 95 7 1769 L18ERM BB1B CompactLogix Processor 1769 L18ERM A LOGIX5318ERM 192 168 1 20 Unrecognized Device 1769 L18ERM A 192 168 1 41 1756 EN2T 1756 EN2T A Backplane 1756 44 4 00 1756 L73 LOGIX5573 Redundancy_update 02 1756 EN2T 1756 EN2T A 03 A 17 2 REDUNDANC j J 192 168 1 42 1756 EN2T 1756 EN2T A H S Backplane 1756 44 4 H 00 1756 L73 LOGIX5573 Redundancy_update 02 1756 EN2T 1756 EN2T A 03 1756 RM2 4 1756 RM2 REDUNDANCY MODULE Address Device Type f oo 1756 L73 LOGIXSS73 a2 1756 EN2T jj os 1756 RM2 A The primary chassis exports first The status displays during export 212 Rockwell Automation Publication 1756 UM535D EN P November 2012 Troubleshoot a Redundant System Chapter 9 In the following example chassis B is the primary chassis Exporting event logs from the RM in chassis B 5 The secondary chassis then exports In the following example chassis A is the secondary chassis Exporting event logs from the RM in chassis A 13 Export Diagnos
214. ions Exceptions are noted The 1756 RM2 A or 1756 RM2XT modules can be used only with other 1756 RM2 A or 1756 RM2XT modules You cannot mix 1756 RM2 A and 1756 RM2XT modules with 1756 RM A 1756 RM B or 1756 RMXT modules Please note that firmware revision 19 052 applies to 1756 L6x controllers only and revision 19 053 applies to 1756 L7x controllers only You cannot use standard ControlNet and EtherNet IP communication modules in enhanced redundancy systems You must use enhanced communication modules in enhanced redundancy systems Enhanced communication modules contain a 2 in their catalog number For example the 1756 EN2T module The redundant controller program cannot contain these tasks Event tasks Inhibited tasks For recommendations and requirements related to programming the redundant controller see Program the Redundant Controller on page 141 You cannot use the Firmware Supervisor feature available in RSLogix 5000 software in an enhanced redundancy system You cannot use SERCOS Motion or Integrated Motion on EtherNet IP in a redundant controller program You cannot use consumed Unicast connections in an enhanced redundancy system If you attempt to use consumed Unicast connections disqualification occurs and qualification of an unsynchronized redundant chassis pair is not allowed You can use produced Unicast connections consumed by remote consumers You cannot use a 1756 EWEB module and any fun
215. iority task is significantly smaller than its period e The total execution time of all your tasks is significantly less than the period of the lowest priority tasks Verifying those settings generally leaves enough time for service communication The example configuration of tasks shown here demonstrates those configuration settings Rockwell Automation Publication 1756 UM535D EN P November 2012 167 Chapter7 Program the Redundant Controller Program to Obtain System Status 168 Example of Periodic Task Configurations Task Priority Execution Time Period Specified 1 Higher 20 ms 80 ms 2 Lower 30 ms 100 ms Total execution time 50 ms In this example the execution time of the highest priority task Task 1 is significantly smaller than its period that is 20 ms is less than 80 ms and the total execution time ofall the tasks is significantly smaller than the specified period of the lowest priority task that is 50 ms is less than 180 ms Tuning the Period Specified You may need to tune the period you specify for your periodic tasks to balance program execution and service communication TIP The crossloading of data during synchronization points extends task scan times in enhanced redundancy systems We recommend that you balance program execution and service communication when the system is synchronized To check for overlaps go online with the controller and access the Task Properties dialog box In the
216. is of a disqualified redundant chassis pair and no other devices in the primary chassis have time synchronization enabled the redundant chassis pair attempts to qualify However in these application conditions the attempt to qualify fails e While CIP Sync technology can handle multiple paths between master and slave clocks it resolves mastership most effectively if you configure the redundant paths so that Time Synchronization is enabled in only the minimum required number of EtherNet IP communication modules For example if your redundant chassis pair has three 1756 EN2T communication modules and all are connected to the same network enable Time Synchronization in only one of the modules Rockwell Automation Publication 1756 UM535D EN P November 2012 81 Chapter 4 82 Configure the EtherNet IP Network e Ifthe primary controller is the Grandmaster the enhanced redundancy system automatically manages the CIP Sync clock attributes so that the controller in the primary chassis is always set to be the Grandmaster instead of the secondary controller This clock management ensures a change to a new Grandmaster when the redundancy system switches over When a switchover occurs these events take place The Grandmaster status transfers from the original primary controller to the new primary controller This transfer can take longer to complete than if Grandmaster status was transferred between devices in a nonredundant system
217. is A O m7 1756 EN2T 5 Primary Secondary The difference between a locked switchover and a normal switchover is that the locked switchover can be initiated only by the user The normal switchover can be initiated by a user or by a fault in the primary chassis Rockwell Automation Publication 1756 UM535D EN P November 2012 133 Chapter6 Configure the Redundancy Modules System Update Lock Attempts The System Update Lock Attempts is where attempts to lock the system are logged This log displays the last four lock attempts and provides this information specific to each attempt Time and date Status for example Locked or Abort Result for example System Locked or Invalid Response Received The status indicated in the System Update Lock Attempts log can be any one of the states listed in this table Table 22 System Update Lock Attempts Log Statuses Status Interpretation Not Attempted A system lock has not been attempted since the last powerup In Progress A lock is in progress Locked The lock was successfully completed Abort The lock attempt failed The reason for the failure is indicated in a Result field If your status is indicated as Abort one of these conditions can exist An error occurred while communicating with the partner redundancy module A module in the secondary chassis does not have a partner in the primary chassis A module pair is incompat
218. ization could not be performed because the communication link between redundancy modules does not exist Nonredundant Compliant Module Exists Synchronization could not be performed because one or more nonredundancy modules are present in one of the chassis Sec Failed Module Exists A module in the secondary chassis has asserted the SYS_FAIL line indicating that it has faulted or failed Local Major Unrecoverable Fault Synchronization was aborted because of a local major unrecoverable fault Partner Has Major Fault Synchronization was aborted because the partner module has a major fault Sec SYS_FAIL_L Subsystem Failed The test of the SYS_FAIL line in the secondary chassis failed Sec RM Device Status Comm Error Synchronization was aborted because the secondary redundancy module s status indicates a communication error Sec RM Device Status Major Recoverable Fault Synchronization was aborted because the secondary redundancy module s status indicates a major recoverable fault Sec RM Device Status Major Unrecoverable Fault Synchronization was aborted because the secondary redundancy module s status indicates a major unrecoverable fault Incorrect Device State Synchronization was aborted because the device is in the wrong state Primary Module Failed Synchronization was aborted because of a failure in the primary module Primary Failed Module Exists A module in the primary
219. ize of data transferred use this equation to estimate your controllers crossload time for each program 1756 L6x Controllers Crossload time per sync point ms DINTs 0 00091 0 6 ms 1756 L7x Controllers The following equations apply when a 1756 L7x controller is paired with a redundancy module in both chassis in a redundancy system Table 24 Crossload Times for 1756 L7x Controllers Paired with Redundancy Module Crossload Time 1756 RM2 A Crossload time per sync point ms DINTs 0 000275 0 54 ms 1756 RM B Crossload time per sync point ms DINTs 0 00043 0 3 ms 1756 RM A Crossload time per sync point ms DINTs 0 00091 0 6 ms Where DINTSs is the size of the data transferred measured in 4 byte words TIP A sync point is a mechanism that the primary controller uses to keep the secondary controller in sync By default at the end of each program scan the primary controller sends the secondary controller the sync point and the secondary controller responds by moving its execution pointer to match the primary controller The default for phases is not to send a sync point Beginning in revision 16 05x the option exists to manipulate the sync points for faster program execution Rockwell Automation Publication 1756 UM535D EN P November 2012 151 Chapter7 Program the Redundant Controller Program to Minimize Scan Times 152 Because your system switchover time is impacted by your total pr
220. kwell Automation Publication 1756 UM535D EN P November 2012 Design an Enhanced Redundancy System Chapter 2 Firmware Requirements If you are using an enhanced redundancy system use only enhanced redundancy system firmware These are the enhanced redundancy system firmware revision bundles e 16 054Enh e 16 080Enh e 16 081Enh e 16 081_kitl e 19 052Enh e 19 053Enh e 19 053_kit1 e 20 054 e 20 054 kitl To download the most recent enhanced redundancy system firmware bundle go to_http www rockwellautomation support com Softwa re Requirements These sections describe required and optional software for use with your enhanced redundancy system Required Software This software is required to use all enhanced redundancy system revisions e RSLogix 5000 software e RSLinx Classic communication software e Redundancy Module Configuration Tool RMCT This utility is installed when you install RSLinx Classic communication software For the most current software versions go to_http www rockwellautomation support com Rockwell Automation Publication 1756 UM535D EN P November 2012 49 Chapter 2 50 Design an Enhanced Redundancy System Optional Software Software in addition to that listed as required software can be needed depending on your enhanced redundancy system program configuration and components Optional software you might need is listed in this table If using ControlNet network Then use this
221. l other components used in the redundant chassis pair are installed IMPORTANT Keep the redundancy module as close as possible to the controller module 1756 RM2 A or 1756 RM2XT modules You cannot mix 1756 RM2 A and IMPORTANT 1756 RM2 A or 1756 RM2XT modules can only be used with other 1756 RM2XT modules with 1756 RM A 1756 RM B or 1756 RMXT modules Installation Requirements Before you install the module be sure to note the following Understand redundant systems and redundant media Verify that the planned modules for each redundant chassis of the pair are identical including firmware revisions Verify that your enhanced redundancy firmware revision is compatible with your planned redundant chassis modules The 1756 RM B module offers a higher level of performance than a 1756 RM A module Both modules can coexist in a redundant system but the highest system performance is achieved when the 1756 RM B modules are used together when used in conjunction with a 1756 L7x controller The 1756 RM2 A module when used in conjunction with a 1756 L7x controller offers higher crossload speeds than the 1756 RM B module Rockwell Automation Publication 1756 UM535D EN P November 2012 57 Chapter 3 A A Install the Enhanced Redundancy System Environment and Enclosure ATTENTION This equipment is intended for use in a Pollution Degree 2 industrial environment in overvoltage Category Il applications as defined in IEC 60664
222. ler Chapter 7 Store a Project While a System is Running If you want to store your controller project in nonvolatile memory while your redundant system is running complete these steps 1 Verify that the redundant chassis are synchronized Chassis Ac Primary with Synchronized Secondary Auto Synchronization State Aways Inthe RMCT access the Configuration tab and set the Auto Configuration parameter to Never 3 In the Synchronization tab click Disqualify Secondary Go online with the secondary controller Offline 1 E RUN No Forces No Edits Upload Redundancy Download IMPORTANT Do not go back online with the primary controller until you have completed this procedure Open the Controller Properties dialog box and click the Nonvolatile Memory tab Click Load Store then lt Store to store the project in nonvolatile memory Inthe RMCT click the Synchronization tab 8 Click Synchronize Secondary and wait for the system to synchronize 10 11 12 13 Click Initiate Switchover Initiate Switchover Go online with the new secondary controller Complete steps 5 and 6 to store the project In the RMCT click the Configuration tab and set the Auto Configuration to your desired setting In the Synchronization tab click Synchronize Secondary You have completed the steps required to store your project while online Rockwell Automation Publication
223. ler is synchronized the system automatically crossloads the project to the secondary controller IMPORTANT Ifthe secondary chassis was qualified and becomes disqualified after you download the project verify that you have enabled the controller for redundancy Controller Properties Redundancy_update General Major Faults Minor Faults Date Time Advanced SFC Execution File Redundancy Nonvolatile Memory Memory Security Redundancy Enabled 1 See the PlantPAx Automation System Reference Manual publication PROCES RM001 Rockwell Automation Publication 1756 UM535D EN P November 2012 177 Chapter7 Program the Redundant Controller Storea Redundancy Project Use this procedure to store an updated project and firmware to the nonvolatile to Nonvolatile Memory memory card of the controller IMPORTANT The controllers use these nonvolatile memory cards Nonvolatile Memory Card 1756 L6x 1784 CF64 or 1784 CF128 CompactFlash cards 1756 L7x 1784 SD1 or 1784 SD2 Secure Digital cards This section describes how to store a project to nonvolatile memory in either of these conditions e Store a Project While the Controller is in Program or Remote Program Mode e Store a Project While a System is Running IMPORTANT We recommend that you store the same project on both controllers nonvolatile memory cards By doing so you can be assured that if a controller primary or secondary loses the project from its intern
224. les Chapter 6 Use the RMCT To access and begin using the RMCT launch RSLinx Classic software and browse to your redundancy module Right click the redundancy module and choose Module Configuration 192 168 1 41 1756 EN2T 1756 EN2T 4 Backplane 1756 A4 4 00 1756 L73 LOGIX5573 NSONL_Example 02 1756 EN2T 1756 EN2T A f 192 168 1 42 1756 EN2T 1756 EN2T A Remove amp Backplane 1756 A4 4 f 00 1756 L73 LOGIX5573 NSONL_Example 02 1756 EN2T 1756 EN2T A 03 1756 RM2 A 1756 RM2 REDUNDANCY Mop _ Upload EDS file From device Security Device Properties Driver Diagnostics Configure Driver Module Configuration b Rockwell Automation Publication 1756 UM535D EN P November 2012 107 Chapter6 Configure the Redundancy Modules When you access the RMCT the dialog box always indicates the status of the redundancy chassis in the bottom left corner 108 Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Redundancy Modules Chapter 6 Identify the RMCT Version You must use a version of the RMCT that is compatible with your redundancy module firmware Beginning with version 20 054 the redundancy module firmware reports back to the Redundancy Module Configuration Tool RMCT as to which version of the RMCT is compatible In the case of an incompatibility the RMCT will show only the Module Info tab and indicate the version that the firmware i
225. lid Keepers and Signatures This example shows a Keeper Status dialog box where the ControlNet network that is comprised of valid keepers and signatures Valid Keeper Status and Signatures 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 Oxda8adced 01 YES YES OxdaSadced 06 NO YES Oxda8adced 07 NO YES Oxda8adced 09 NO YES Oxda8adced 10 NO YES OxdaBadced Unconfigured Keeper The example below shows the Keeper Status dialog box where a module has an unconfigured status Besides the status shown the module status display indicates Keeper Unconfigured node address changed This error results when the module s node address has been changed After changing the node address the module was used as a replacement and inserted into the redundant chassis Figure 63 Keeper Status Unconfigured 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 Ox4a8ad4ced 0i YES YES Ds4a a4ced 06 NO TES Oxda8adced 07 NO YES Oxda8adced og NO YES OxdaB8adced eat NO
226. lower left portion of the RMCT window after setting the Auto Synchronization parameter to Conditional e Ifyour Auto Synchronization parameter is set to Conditional and your Auto Synchronization state is Conditional Enabled then the system continually attempts to synchronize e Ifyour Auto Synchronization parameter is set to Conditional and your Auto Synchronization state is Conditional Disabled then the system does not automatically attempt to synchronize To change from Conditional Enabled to Conditional Disabled click Disqualify Secondary on the Synchronization tab To change from Conditional Disabled to Conditional Enabled click Synchronize Secondary on the Synchronization tab 114 Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Redundancy Modules Chapter 6 Chassis ID The chassis ID parameter is used to assign a generic label to the chassis that house the redundancy modules The available chassis labels are Chassis A and Chassis B If you change the chassis label in the RMCT of the primary redundancy module the secondary module and chassis are automatically assigned the other chassis label The chassis label assigned to the module remains associated with the same physical chassis regardless of its primary or secondary control designation Enable User Program Control If you plan to use MSG instructions in your controller program to initiate a
227. ly indicates that one of the redundancy modules has been disconnected In addition the dimmed secondary chassis log indicates that the module is not connected Rockwell Automation Publication 1756 UM535D EN P November 2012 Troubleshoot a Redundant System Chapter 9 To resolve this anomaly check the intermodule cable that connects the redundancy modules Verify that it is properly connect and is not severed Also if the Auto Synchronization parameter of this system is not set to always use the commands in the Synchronization tab to synchronize that chassis once the anomaly is resolved Redu ndancy Module Missing To determine if a missing redundancy module caused a state change and switchover access the Event Log of the chassis that is currently the primary chassis Figure 65 Event Log with Partner RM Screamed Event Chassis B Log Time 168340 9 25 2009 11 06 32 9 168339 9 25 2009 11 06 32 9 168338 9 25 2009 11 06 32 9 L 168337 9 25 2009 11 06 32 9 168336 9 25 2009 11 00 49 0 168335 9 25 2009 11 00 48 9 168334 9 25 2009 11 00 34 3 Module Description 1756 RM 2 C2 Bridge Connection Deleted 1756 RM 2 C2 Bridge Connection Deleted 1756 RM 2 30 Switchover Attempted 1756 RM 2 57 Partner RM Screamed 1756 RM2 1E Chassis Redundancy State changed to QSwP 1756 CN 31 Transition To Qualified Secondary 1756 CN 30 Transition To Qualifying Secondary RM Scream
228. m Event History r uto Update r Partner Log ON C OFF C OPEN CLOSE Export Selection Export AII 120 Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Redundancy Modules Chapter 6 Event Classifications Each event identified and logged is classified You can use these classifications to identify the severity of the event and determine if additional action is required Figure 30 Event Classifications in the Event Log Tab a ee ce pre cep ce ey Auto Update _ Partner Log ON OFF E OPEN CLOSE Export Selection Export AII Chassis Classification Module Name Description 11 16 2010 14 12 54 907 1756 RM 91 Response to Open Bridge Connection ops 1756 RM 90 Request to Open Bridge Connection Starts Stops 747424 11 16 2010 14 12 54 876 747423 11 16 2010 14 12 54 875 747422 11 16 2010 14 12 54 875 747421 11 16 2010 14 12 54 874 1756 AM 91 Response to Open Bridge Connection Starts Stops 1756 AM 90 Request to Open Bridge Connection Starts Stops 1756 AM D Communication error Minor Fault 1756 RM 2C Autoqualification Trigger Qualification 11 16 2010 14 12 54 906 7 747433 1116 2010 14 12 54 905 2 1756 L75 35 Partner Connection Opened State Changes 747432 11 16 2010 14 12 54 904 5 1756 EN2T 33 Partner Ping Successful Configuration 747431 11 16 2010 14 12 54 897 5 1756 EN2T 10 Partner Connection Opened State
229. m Update System Event History m Auto Update Partner Log ON C OFF OPEN CLOSE Export Selection Chassis A Event Log Time Module Description Classificati a 1756 RM2 11 Autoqual Option Setto Cond Confiqurati 1756 RM2 1A Chassis Redundancy State c State Cha 324223 9 10 2009 16 33 45 1 324222 9 10 2009 16 33 26 4 NM wWM Mh ww iy 324221 9 10 2009 16 33 28 4 1 756 CN 21 Equally Able To Control State Cha 324220 9 10 2009 16 33 28 4 1756 CN 14 Enter Qualification Phase 4 Qualification 324219 9 10 2009 16 33 28 4 1756 RM 2 2E Qualification Complete Qualification 324218 9 10 2009 16 33 28 4 1756 CN 13 Enter Qualification Phase 3 Qualification 324217 9 10 2009 16 33 27 4 1756 CN 12 Enter Qualification Phase 2 Qualification Chassis B Log Time 166498 9 10 2009 16 33 45 1 166497 9 10 2009 16 33 28 4 166496 9 10 2009 16 33 28 4 166495 9 10 2009 16 33 26 8 166494 9 10 2009 11 54 01 4 Module Description Classificati 1756 RM2 11 Autoqual Option Setto Cond Configurati 1756 RM2 1E Chassis Redundancy State c State Cha 1756 CN 31 Transition To Qualified Seco State Cha 1756 CN _ 30 Transition To Qualifying Sec State Cha 1756 RM 2 91 Response to Open Bridge C Starts Stops IW MN Ww wig 206 Rockwell Automation Publication 1756 UM535D EN P November 2012 Chassis A PwQS and start
230. m upload e RSLinx DDE OPC client e PanelView polling of a Logix5000 controller ControlLogix ControlNet communication modules provide 131 total CIP connections Consider these points when using CIP connections with ControlLogix ControlNet communication modules e Three of the 131 CIP connections are reserved for redundancy The three redundant system CIP connections always appear to be in use even when no connections are open e You can use the remaining 128 CIP connections in any manner that your application requires such as the examples listed above ControlLogix EtherNet IP communication modules provide 259 total CIP connections Consider these points when using CIP connections with ControlLogix EtherNet IP communication modules e Three of the 259 CIP connections are reserved for redundancy e You can use the remaining 256 connections in any manner that your application requires such as the examples listed above Rockwell Automation Publication 1756 UM535D EN P November 2012 33 Chapter2 Design an Enhanced Redundancy System Power Supplies and Redundant Power Supplies in Enhanced Redundancy Systems You can use any of the standard or redundant power supplies listed in Components Available for Use in a Redundant Chassis Pair on page 24 in an enhanced redundancy system Redundant Power Supplies Typically enhanced redundancy systems use standard power supplies You can choose to use redundant power supplies to mai
231. meter is at the proper value before you make any changes to your redundant system This helps prevent system errors For example if you are upgrading your redundant system firmware verify that this parameter is set to Never or Conditional before disqualifying your secondary chassis If this parameter is Always you cannot properly disqualify your chassis and conduct the update Use this table to determine the Auto Synchronization setting that best suits your application If you use this parameter Then this synchronization behavior results Never The system remains in the same state that is either synchronized or disqualified until one of these events takes place e Acommand is issued from the RMCT to either synchronize or disqualify e The controller commands synchronization or disqualification through the use of a MSG instruction For this to occur Enable User Program Control must be checked A fault on the primary causes a switchover Always The system automatically synchronizes on a regular basis If you attempt to disqualify the system by using the Disqualify Secondary command in the RMCT the resulting disqualification is temporary as the system automatically qualifies and synchronizes again If the controller program disqualifies the system the resulting disqualification is also temporary Conditional The system behavior with this setting is dependent on the Auto Synchronization state of your system found in the
232. mit to Tex Only Y Find All Replace With CNet for_l0 Zj Replace Replace All All Routines Find Where Close Direction C Up Down v Wrap P Match Whole Word Only Help Find Within Function Block Diagrams Ladder Diagrams Sequential Function Charts Structured Text Find Within gt gt i Pe 3 From the Find What pull down menu choose Local 4 From the Replace With pull down menu choose the name of the communication module where the remote I O was placed From the Find Where pull down menu choose All Routines Click Find Within gt gt Select Ladder Diagrams o Nn Aay Check Instruction Operands lt lt Find Within i Options Instruction Main Operand Comments Instruction Operands Instructions Rung Comments Rung Types Rockwell Automation Publication 1756 UM535D EN P November 2012 Convert from a Nonredundant System Appendix D 9 Click Replace All The find replace is completed and the results are indicated in the Search Results tab Replacing Local with CNet_for_IO Searching through MainProgram MainRoutine Replaced Rung 0 XIC Operand 0 XIC Local 2 1 Data 10 Replaced Rung 0 OTE Operand 0 OTE Local 3 0 Data 6 keine kys 1 MOV oo OQ pkai 231 data 25 indicator Replace Aliases to Local If your program uses alias tags for the I O modules that you are moving 1 0 Ta gs comple
233. mmunication module in the remote chassis that holds the consuming controller uses the Comm Format None Critical messages from a remote chassis to redundant chassis use cached connections Active tags on scan per controller are less than 10 000 tags second 1 Note that the project loaded on the primary controller is automatically crossloaded to the secondary controller when sychronization occurs 282 Rockwell Automation Publication 1756 UM535D EN P November 2012 Changes to This Manual Appendix G Enhanced Redundancy Revision History With the availability of new controllers modules applications and RSLogix 5000 software features this manual has been revised to include updated information This appendix briefly summarizes changes that have been made with each revision of this manual Reference this appendix if you need information to determine what changes have been made across multiple revisions This may be especially useful if you are deciding to upgrade your hardware or software based on information added with previous revisions of this manual This table lists the publication revision publication date and changes made with the revision Table 52 History of Changes Publication Revision and Date Topic 1756 UM535C EN P July 2012 Updated features not supported Addend information about using signed and unsigned firmware Updated 1 0 modules in enhanced redundancy systems revision 19 053 to the
234. modules or you can check the keeper status by using RSNetWorx for ControlNet software TIP To avoid anomalies with the Keeper Status always reset the ControlNet module configuration of a module being used as a replacement before inserting and connecting the module in a ControlNet network For more information about resetting the ControlNet module configuration see Automatic Keeper Crossloads on page 102 Rockwell Automation Publication 1756 UM535D EN P November 2012 Troubleshoot a Redundant System Chapter 9 Check the Module Status Display If the module status display of the ControlNet modules in the redundant chassis indicate these errors you need to take corrective action Keeper Keeper Keeper Keeper Keeper Keeper Unconfigured Unconfigured data format changed Unconfigured slot changed Unconfigured net address changed Signature Mismatch None Valid on Network Check Keeper Status in RSNetWorx for ControlNet Software To check the status of keepers on the ControlNet network open RSNetWorx for ControlNet access the Keeper Status from the Network menu Figure 62 Network Keeper Status Network Single Pass Browse Continuous Browse 3 Online F10 Enable Edits Cancel Edits Upload from Network Download to Network Download Minimum to Network Rockwell Automation Publication 1756 UM535D EN P November 2012 217 Chapter9 Troubleshoot a Redundant System Va
235. mpted Not attempted Not attempted m Locked Switchover Attempts Locked Switchover History Initiation Time Status Result N Not attempted E N 1 Not attempted N 2 Not attempted N 3 Not attempted Refresh 130 Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Redundancy Modules Chapter 6 System Update Commands The three system update commands are available only when accessing a primary redundancy module These commands are not available when accessing the secondary redundancy module TIP While you are completing tasks to update the system by using the system update commands you cannot access these tabs in the RMCT e Configuration Synchronization e Synchronization Status Attempting to access any of these tabs while the system is locked or is completing a locked switchover results in a error dialog box Lock For Update The Lock for Update command lets you to synchronize a redundant chassis pair in these conditions e The secondary redundancy module uses updated firmware and an updated RSLogix 5000 software application program version e The running primary redundancy module uses a previous firmware revision and previous RSLogix 5000 software application program version The Lock for Update command is available only when all the modules in the primary chassis have no compatibility anomalies Before issuing the lock command
236. n Ta Nualifninn Seeandans j Stangl Mi lt 208 Rockwell Automation Publication 1756 UM535D EN P November 2012 Troubleshoot a Redundant System Chapter 9 6 Examine the range of time in between the start of the event and the end of the event to find the error that caused the disqualification IMPORTANT time has passed since the last disqualifying event Be aware that this range of time can be very large depending on how much Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History Export Selection Export All Auto Update Partner Log CON OFF OPEN CLOSE Chassis B Log Time S Module Na Description Classific 9945 3 24 2012 08 53 44 795 1 1756 AM2 C2 Bridge Connection Deleted Starts 9944 3 24 2012 08 53 44 775 1 1756 AM 2 C2 Bridge Connection Deleted Starts End 9943 een 2 08 53 bes foo 1 1756 RM2 C2 Bridge Connection Deleted Starts 9942 1 1756 AM 2 C2 Bridge Connection Deleted Starts rom JE 1 1756 RM 2 1D Chassis Redundancy State changed Ks State CI 9940 7 7 1 1756 AM 2 C2 Bridge Connection Deleted Starts 9939 3 24 2012 08 53 44 716 1 1756 RM 2 C2 Bridge Connection Deleted Starts o oo Co 9938 3 24 2012 08 53 44 715 1 1756 AM 2 C2 Bridge Connection Deleted Starts Error 9937 3 24 20 2 08 a A at 2 1756 EN2T F Partner Connection cossi Synchre 9935 2 1756 EN2T 1
237. n begins Figure 19 IP Addresses in RSLinx Classic Software aop AB_ETHIP 2 Ethernet T 4 192 168 1 3 1 56 EN2T 1756 EN2T A SP 4 192 168 1 4 1 756 EN2T 1756 EN2T A Rockwell Automation Publication 1756 UM535D EN P November 2012 79 Chapter 4 80 Configure the EtherNet IP Network Static versus Dynamic IP Addresses We recommend that you use static IP addresses on EtherNet IP communication modules in enhanced redundancy system network failure occurs modules using dynamic IP addresses can be assigned new addresses when the failure is resolved If the IP addresses change your application could experience a loss of control or other serious complications with your system i ATTENTION If you use dynamic IP addresses and a power outage or other You cannot use dynamic IP addresses with IP address swapping Reset the IP Address for an EtherNet IP Communication Module If necessary you can reset a 1756 EN2x communication module s IP address to the factory default value To return to the factory default set the module s rotary switches to 888 and cycle power After cycling power to the EtherNet IP communication module you can either set the module s switches to the desired address or set the switches to 999 and use one of these methods to set the IP address e BOOTP DHCP server e RSLinx Classic communication software e RSLogix 5000 programming software Rockwell Automation Publication 175
238. n module automatically changes its IP address to thenext highest value When a switchover occurs the EtherNet IP communication modules swap IP addresses For example if you assign IP address 192 168 1 3 to both EtherNet IP communication modules in a partnered set on initial system operation the secondary EtherNet IP communication module automatically changes its IP address to 192 168 1 4 This graphic shows a partnered set of EtherNet IP communication modules after system operation begins Figure 18 EtherNet IP Communication Modules IP Addresses After System Operation Begins IP Address 192 168 1 3 IP Address 192 168 1 4 Primary Chassis Secondary Chassis Pome ne Poor f oc x Sp S HHS a ZH ZHH A aa i z L iS HHS N H N m H Hg L _ TIP Do not assign IP addresses to EtherNet IP communication modules outside the partnered set to values that conflict with those used in the partnered set In the previous example the partnered set uses 192 168 1 3 and 192 168 1 4 Use 192 168 1 5 or higher for all EtherNet IP communication modules outside the partnered set This graphic shows the partnered set of EtherNet IP communicationmodules in RSLinx Classic software after system operatio
239. ncy systems revision 19 052 or later 1756 A5XT ControlLogix XT 5 slot chassis 1756 A7 ControlLogix 7 slot chassis 28 1756 A7XT ControlLogix XT 7 slot chassis 25 70 C 13 158 F 1756 A7LXT ControlLogix XT 7 slot chassis 25 60 C 13 140 F 1756 A10 ControlLogix 10 slot chassis 1756 A13 ControlLogix 13 slot chassis 1756 A17 ControlLogix 17 slot chassis Communication 1756 CN2 B ControlLogix ControlNet bridge module dul rape 1756 CN2R B ControlLogix redundant media ControlNet bridge module 1756 CN2RXT ControlLogix XT ControlNet bridge module 1756 EN2T ControlLogix EtherNet IP bridge module 1756 EN2F ControlLogix EtherNet IP fiber bridge module This component 32 is available with enhanced redundancy systems revision 20 054 or later 1756 EN2TR ControlLogix EtherNet IP 2 port module This component is available with enhanced redundancy systems revision 19 052 or later 1756 EN2TXT ControlLogix XT EtherNet IP bridge module 24 Rockwell Automation Publication 1756 UM535D EN P November 2012 Design an Enhanced Redundancy System Chapter 2 Table 4 Components Available for Use in a Redundant Chassis Pair Product Type Cat No Description Page Controllers 1756 L61 1756 ControlLogix controllers L62 1756 L63 1756 L64 1756 L63XT ControlLogix XT controller 1756 L65 ControlLogix controller This component is available with enhanced redundancy systems revision 19 052 or later 29 1756 L72
240. ncy modules is cycled the redundancy module will power up with the time set to when the power was lost If the partner redundancy module has remained active during this time the time set in that module will be automatically transferred to the powering up module If a power failure event happens so that both modules are shut off reset the time and date in the RMCT Setting and verifying the date and time settings after a power loss will help with troubleshooting if an error or event occurs Rockwell Automation Publication 1756 UM535D EN P November 2012 191 Chapter8 Monitor and Maintain an Enhanced Redundancy System Verify System Qualification After you have completed programming your redundant system and have downloaded your program to the primary controller check the system status to verify that the system is qualified and synchronized TIP The system qualification process can take several minutes After a qualification command or a switchover allow time for qualification to complete before taking action based on the qualification status Check Qualification Status via Module Status Displays You can view qualification status by using the status displays and indicators of the secondary redundancy module and the primary and secondary ControlNet and EtherNet IP communication modules Table 35 Synchronized System Primary Chassis Display Secondary Chassis Display Redundancy Module Communication Module Redundancy Module Communi
241. ncy system consider these points e Ifthe standard redundancy system uses a 1757 SRM redundancy module you must replace it with a 1756 RM redundancy module e You must upgrade all ControlNet or EtherNet IP communication modules e You must upgrade the firmware on all controllers e Depending on the enhanced redundancy system revision to which you are upgrading you may need to upgrade software Rockwell Automation Publication 1756 UM535D EN P November 2012 239 AppendixC Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Upgrade System Components IMPORTANT Safely shut down system and controlled equipment Be sure to place the system and controlled equipment in a state where they can be safely shut down prior to beginning this upgrade The available components to which you can upgrade when converting a standard redundancy system to an enhanced redundancy system depends on the enhanced redundancy system revision level You must complete these steps when upgrading system components Each step is described in detail in the rest of this appendix e Upgrade the System Software e Upgrade the Controllers e Replace Communication Modules e Steps After System Components Upgrade Complete these steps before upgrading the necessary components to an enhanced redundancy system 1 Verify that the standard redundancy system is offline 2 Remove power from both the primary and secondary chas
242. ndancy modules via the 1756 RMCx fiber optic communication cable The cable is not included with the redundancy module Before installation order this fiber optic communication cable separately Redundancy cables available from Rockwell Automation include the following Table 11 Fiber optic Cable Length Fiber Cable Cat No Length 1756 RMC1 1m 3 28 ft 1756 RMC3 3 m 9 84 ft 1756 RMC10 10 m 32 81 ft Rockwell Automation Publication 1756 UM535D EN P November 2012 63 Chapter 3 64 Install the Enhanced Redundancy System The cable connection is made at the bottom of the module in a downward orientation There is enough space between the transmit and receive connectors so you can use the LC connector coupler Using this coupler keeps the fiber optic cable from bending so you can connect and disconnect the cable without removing the module from the chassis A ATTENTION Consider these points when connecting the fiber optic cable The redundancy module communication cable contains optical fibers Avoid making sharp bends in the cable Install the cable in a location where it will not be cut run over abraded or otherwise damaged The redundancy module contains a single mode transmitter Connecting this module to a multi mode port will damage any multi mode devices Under certain conditions viewing the optical port can expose the eye to hazard When viewed under some conditions the optical port can expose the ey
243. ndle this equipment Touch a grounded object to discharge potential static Wear an approved grounding wrist strap Do not touch connectors or pins on component boards Do not touch circuit components inside the equipment Use a static safe workstation if available Store the equipment in appropriate static safe packaging when not in use Removal and Insertion Under Power RIUP WARNING When you insert or remove the 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 the module and its mating connector Worn contacts may create electrical resistance that can affect module operation European Hazardous Location Approval The following applies when the product bears the Ex Marking This equipment is intended for use in potentially explosive atmospheres as defined by European Union Directive 94 9 EC and has been found to comply with the Essential Health and Safety Requirements relating to the design and construction of Category 3 equipment intended for use in Zone 2 potentially explosive atmospheres given in Annex II to this Directive Compliance with the Essential Health and Safety Requirements has been assured by compliance with EN 60079 15 and EN 60079 0 58 Rockwell Automation Publication 1756 UM535D EN P
244. ng steps detail the installation process for an enhanced redundancy system They also explain how to install the redundant modules These steps Redundancy System include the following 1 Installing the software 2 Installing the hardware 3 Connecting the fiber optic communication cable to the redundancy modules 4 Updating the firmware 5 Designating a primary and secondary chassis Step 1 Install the Software These steps detail the installation process for an enhanced redundancy system Before you download and update software for use with your redundant system use one of these methods to fully shutdown RSLinx Classic software e Right click the RSLinx Classic icon in the notification area of the screen and choose Shutdown RSLinx Classic e With RSLinx Classic software open from the File menu choose Exit and Shutdown VS RSLinx Classic Gateway RS ho File Edit View Communications St Open Project Ctrl O Select Default Project Exit Exit and Shutdown Install the Software Obtain and install the software required for your redundant system configuration and application This includes the latest redundancy firmware version bundle with the RMCT For more information on required software versions for redundant system configuration see Software Requirements on page 49 Use the installation instructions or release notes provided with each software version for installation procedures and requirements
245. nication module 242 requested packet interval over EtherNet IP 77 requirements 49 ControlNet 38 EtherNet IP 42 firmware 49 reset redundant module 75 restrictions 22 1756 RM2 A 22 1756 RM2XT A 22 enhanced redundancy system 22 revisions 241 ring node DLR 88 RIUP 58 RMCT 51 105 1756 RM2 A 54 Event Log 206 troubleshoot 206 version 109 RMCT See Redundancy Module Configuration Tool rotary switches 244 RSLinx Classic 51 251 shutdown 53 RSLinx communication software 49 53 86 RSLogix 5000 software 51 86 use to troubleshoot 201 RSU redundancy system update 250 S scan time best performance 152 concise programming 157 crossload 149 efficient crossloads 154 156 minimize 152 158 multiple controllers 152 number of programs 153 scan dependent logic 160 schedule ControlNet 98 secondary 246 secondary chassis 19 designation 71 74 intallation 63 set IP address 86 SFP 230 small form pluggable 67 transceiver 67 Rockwell Automation Publication 1756 UM535D EN P November 2012 291 Index 292 shutdown RSLinx Classic 53 signed and unsigned firmware 17 SIL3 unsupported feature 17 single point of failure redundant fiber ports 16 small form pluggable SFP 67 sockets 1756 EN2T 85 1756 EN2TR 85 software 49 FactoryTalk Alarms and Events 50 FactoryTalk Batch 50 FactoryTalk View Site Edition 50 install 53 optional 50 Redundancy Module Configuration Tool 49 required 49 RSLinx communication software 49 53 86 RSL
246. no communication is taking place Red lt 1 second The module has been started and has established partner communication No action required Solid red The module has experienced a critical communication failure Cycle power to clear the fault If the major fault does not clear replace the module Flashing green gt 250 ms Communication activity is present No action required 232 Rockwell Automation Publication 1756 UM535D EN P November 2012 Status Indicators Appendix A Chassis State Status Indicator The Chassis State PRI status indicator identifies whether the chassis is primary The PRI status indicator on the primary redundancy module remains solid green and the PRI status indicator on the secondary redundancy module remains off Redundancy Module Fault Codes and Display Messages Redundancy modules may experience any of these faults Table 46 Module Fault Codes Fault Type Description Minor Recoverable This fault type results in these conditions The fault does not stop redundancy operations and provides you with a recovery mechanism The module may clear some minor recoverable faults on its own Minor Nonrecoverable This fault type results in these conditions The fault does not stop redundancy operations e No recovery mechanism is available Major Recoverable The fault impacts redundancy operations although the effect may not be immediate For example if the fault occur
247. nsfer sizes measured in DINTs 4 byte words and are used to calculate the estimated crossload time TIP To get these attributes you do not need to have the secondary chassis installed or operating If you do not have the secondary chassis operating the attribute values read indicate what data sizes would be transferred if the secondary chassis was in use This table indicates the two attributes you may choose to get specific to the crossload data transfer size Get the attribute value that meets your application requirements If you need the Then get this attribute value Data size of the last data transferred during the last crossload LastDataTransferSize Data size of the largest crossload of data MaxDatalransferSize Remember that the LastDatalransferSize attribute refers to the transfer size of the previous crossload and synchronization point which occurred prior to the program containing the GSV instruction If you need to measure the crossloaded data from the last program in the task s program list you may need to add an additional program at the end of the task that acquires the LastDataTransferSize value from the program that was formerly at the end of the task Rockwell Automation Publication 1756 UM535D EN P November 2012 Controller 1756 L7x Program the Redundant Controller Chapter 7 Equation for Estimating Crossload Times After you have either the size of the last data transfer or the maximum s
248. nt chassis Yes Enhanced Yes Redundancy System Revision 19 052 or later Via a bridge No Yes Universal Remote 1 0 Via a bridge Yes Yes Data Highway Plus Via a bridge Yes Yes 1 To avoid a brief loss of communication with the redundant chassis pair in the event of a switchover we recommend that you connect the HMI to the redundant chassis pair via a bridge from an EtherNet IP network to a ControlNet network For more information see Possible Communication Delays on EtherNet IP Networks on page 36 Rockwell Automation Publication 1756 UM535D EN P November 2012 43 Chapter2 Design an Enhanced Redundancy System 0 Placement In an enhanced redundancy system you can place I O modules in these locations e Same ControlNet network as redundant controllers and communication modules e Same EtherNet IP network as redundant controllers and communication modules e DeviceNet network connected via a bridge e Universal Remote I O network connected via a bridge IMPORTANT You cannot install 1 0 modules in the redundant chassis pair You can only install 1 0 modules in remote locations accessed over the networks in this list You can connect to remote 1 0 modules over an EtherNet IP network in an enhanced redundancy system revision 19 052 or later 1715 Redundant 1 0 Systems Beginning with the enhanced redundancy system revision 19 052 or later you can connect to 1715 Redundant I O systems over an EtherNet IP network
249. ntain power to a ControlLogix chassis in the event that one of the supplies loses power Use these hardware components to connect redundant power supplies e Two redundant power supplies for each chassis e One 1756 PSCA chassis adapter module for each redundant chassis e Two 1756 CPR cables for each redundant chassis to connect the power supplies to the 1756 PSCA adapter e Optional user supplied annunciator wiring to connect the power supplies to remote input modules Figure 4 Redundant Power Supplies with Redundant Chassis 1756 PA75R or 1756 PB75R Power Supplies 1756 CN2R 1756 IB16D 1756 0B16D 1756 CN2R _ 8a T l l Annunciator Wiring 1756 CPR optional Cables we 1756 CPR gt Cables co en Secondary Chassis 1756 L75 1756 CN2R 1756 EN2TR For more information about redundant power supplies see the ControlLogix Selection Guide publication 1756 SG001 34 Rockwell Automation Publication 1756 UM535D EN P November 2012 Design an Enhanced Redundancy System Chapter 2 EtherNet IP Networks with The use of EtherNet IP networks in an enhanced redundancy system is primarily R e du n d ant Syst ems dependent on your system revision IMPORTANT A remote chassis c
250. ntroller Redundancy Status Chassis Id A Chassis State Primary with Synchronized Secondary For more information about the REDUNDANCY object attributes see Appendix E Redundancy Object Attributes on page 273 Rockwell Automation Publication 1756 UM535D EN P November 2012 169 Chapter7 Program the Redundant Controller Prog ram Logic to Run Aftera lf your application requires certain logic or instructions to be executed after a Switchover switchover then use programming and tags similar to that shown in this example Figure 52 Precondition Used to Run Logic After Switchover Ladder Logic This GS instruction is used to obtain the chassis ID of the primary chassis that is the chassis that is in control SY Get System Value Class Name Redundancy Instance Name Attribute Name PhysicalChassisID Dest Prim_Chassis_ID_Now 1 If this is the first program scan then use the current primary chassis ID as the chassis ID for the last scan SFS ov Move Source Prim_Chassis_ID_Now 4 Dest Prim_Chassis_ID_Last 0 If a switchover occurs the chassis ID changes The NEG instruction compares the current and last primary chassis ID values If the values are different the Switchover_Occurred bit is turned on In addtion the current primary chassis ID is moved into the last chassis ID EQ Switchover_Occurred Not Equal Source A Prim_Chassis_ID_Now 1 Source B Prim_Chassis_ID_Last 0 Ow Move Source Prim_Chassis_ID_Now 1 De
251. nts 42 set address 86 troubleshoot lost connection 220 use of CIP Sync technology 35 81 83 with HMI 46 Ethernet IP CPU usage 77 EtherNet IP communication modules 56 event classification 121 Event Log controller event 226 qualification events 74 RMCT 206 Event Log tab 120 129 clearing a fault 129 event classifications 121 export data for all events 127 128 export single event data 124 126 extended event information 123 execution continuous task 145 periodic task 147 export data for a single event 124 126 Rockwell Automation Publication 1756 UM535D EN P November 2012 export data for all events 127 128 export diagnostics button 214 export event log 124 128 extended event information 123 F FactoryTalk software 16 features available in system revision 19 052 only 35 fiber optic cable 67 connect 63 redundancy channels 65 fiber optic communication cable 52 firmware 67 bundles 49 download 54 revision 49 signed and unsigned 17 update 67 71 firmware bundle 51 flash upgrade 67 hardware install 54 HMI blind time Ethernet 21 Human Machine Interface HMI 46 48 use over ControlNet 47 use over EtherNet IP 46 1 0 1715 Redundant 1 0 systems 16 35 44 in enhanced redundancy system revisions 18 multicast 278 over EtherNet IP network 16 placement 18 44 install chassis 55 communication modules 56 controller 56 hardware 52 54 power supply 54 55 primary chassis 54 62 redundancy module 57 secondary chas
252. o find out what happened Ifyou 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 Ifyou see a SYS_FAIL_L Inactive event within a few hundred milliseconds then a cable is probably disconnected or broken A communication module pulses the SYS_ FAIL signal when the module loses its connection to the network Look for a Transition to Lonely event to see which module lost its connection The partner RM has been connected The partner 1756 RM powered up or become connected by the fiber optic cable The partner RM screamed The partner 1756 RM lost power has an unrecoverable fault or was removed An 1756 RM has circuits that hold power long enough for it to send a message to its partner over the fiber optic interconnect cable The 1756 RM sends the message even after you remove it from the chassis This message is called a scream The scream lets the partner 1756 RM tell the difference between a broken fiber optic interconnect cable and the power loss or removal of the primary 1756 RM e Ifthe fiber optic cable breaks then there isn t a switchover Ifthe redundancy module loses power or is removed then there is a switchover Transition to lonely A communication module doesn t see any other devices on its network This usually means th
253. oduct type of the redundancy module Product Code CIP product code for the redundancy module Revision Major and minor revision information for the redundancy module Redundancy Module Serial Serial number of the redundancy module Number Product Name Predefined catalog name of the redundancy module General Status General state of the redundancy module Possible values include Startup Load Fault and OK Major Fault Redundancy module s major fault status When a major fault is detected the system does not provide redundancy support Minor Fault Redundancy module s minor fault status When a minor fault is detected the system continues to provide redundancy support Error Code Error code related to the fault if one exists Error Message Text based message describing the error if a fault exists Recovery Message Text based message that indicates the recovery from a fault Total Indicates the number of channel switchovers that have occurred from CH1 to CH2 and vice versa on the module since its last powerup It is reset to 0 automatically by firmware on a power cycle Periodic Indicates the number of switchovers that have occurred between CH1 and CH2 over the last 10 second interval The counter is constantly updated to reflect the value recorded at every 10 second interval The counter is automatically reset to 0 ona power cycle Max Periodic Switchovers The maximum number recorded in the Periodic coun
254. odule Status Display Description PRIM Primary redundancy module The module is operating as the primary module No action required DISQ Disqualified secondary redundancy module Check the secondary partner module s type and revision QFNG Qualifying secondary redundancy module Redundant system status No action is required SYNC Qualified secondary redundancy module Redundant system status No action is required LKNG Secondary redundancy module that is in process of locking for update LOCK Secondary redundancy module that is locked for update Exxx Major fault has occurred xxx represents an error or fault code with the two least significant characters in decimal Use the Error ID code to diagnose and address the error For more information on error codes see Redundancy Module Fault Codes and Display Messages on page 233 EEPROM Update Required On board EEPROM is empty Replace the module BOOT Erase Error Error in erasing NVS device while updating boot image Cycle power to the module If the error persists replace the module BOOT Program Error Error in writing in NVS device while updating boot image Cycle power to the module If the error persists replace the module APP Erase Error Error in erasing NVS device while updating application image Cycle power to the redundancy module If the error persists replace the module APP Program Error Error in writing in NVS device while updating application image Cycle power to the redundancy mod
255. ogix 5000 software 86 RSNetWorx for ControlNet 50 RSNetWorx for EtherNet IP 50 RSView32 50 upgrade 241 251 status of qualification 74 via module status display 192 status indicators 1756 RM 200 1756 RM2 A 200 227 1756 RM2XT A 227 CH1 229 CH2 229 redundancy module 227 use to troubleshoot 200 subnet 78 supervisor node DLR 87 switchover 19 description 20 example 133 locked attempts 135 logic after 170 monitor synchronization after 196 test 195 synchronization automatic synchronization 114 default 145 description of 19 monitor after switchover 196 Synchronization Status tab 119 Synchronization tab 116 119 attempts log 117 commands in 117 system qualification system synchronization 19 system conversion 265 system event edit comment 137 save history 137 System Event History tab 136 system overhead time slice 166 optimize program 164 System Update commands abort system lock 132 initiate locked switchover 133 lock for update 131 System Update Lock Attempts 134 System Update tab 130 135 commands 131 133 Locked Switchover Attempts 135 System Update Lock Attempts 134 T tags manage 154 task 147 continuous execution 145 optimize execution 163 168 periodic 167 recommended 145 time and date 115 transceiver SFP 67 troubleshoot 199 226 check status indicators 200 controller event 226 EtherNet IP lost connection 220 lost EtherNet IP connection 220 missing redundancy module 223 qualification abort 225 redundancy
256. ogram scan time there are several aspects of your program that must be as efficient as possible to facilitate the fastest possible switchover The sections that follow indicate methods of making your program more efficient to minimize your program scan time These methods make your program more efficient and minimize program scan times e Usea 1756 L7x Controller with a 1756 RM2 A Redundancy Module e Use Multiple Controllers e Minimize the Number of Programs e Manage Tags for Efficient Crossloads e Use Concise Programming Use a 1756 L7x Controller with a 1756 RM2 A Redundancy Module Beginning with enhanced redundancy system revision 19 053 you can use 1756 L7x controllers in your application Relative to the redundancy module being used the 1756 L7x controllers scan the controller program faster than 1756 L6x controllers The 1756 L7x controllers also scan the controller program fastest if the enhanced redundancy system uses the 1756 RM2 A redundancy module IMPORTANT Only the 1756 L72 1756 L73 1756 L74 and 1756 L75 controllers can be used in conjunction with the 1756 RM2 A redundancy modules and revision 19 053 See Components Available for Use in a Redundant Chassis Pair on page 24 If your application needs better controller performance we recommend that you update from 1756 L6x controllers to 1756 L7x controllers and use 1756 RM2 A redundancy modules Use Multiple Controllers When possible use m
257. ogram scan is increased However the watchdog timer is not reset and continues to countdown from the beginning of the task that was started by the old primary controller Therefore the watchdog timer must be configured to account for the potential of additional program scans Rockwell Automation Publication 1756 UM535D EN P November 2012 175 Chapter7 Program the Redundant Controller We recommend that you reevaluate the watchdog times in your application if either of these events occur e A second controller is added to a redundancy chassis e The application in a second controller that is already in the system is modified Figure 54 Watchdog Configured for Redundancy Switchover l l l l Program 2 Program 3 Switchover l l l l l l l l l l l l Task l i Crossload l l l l l l l l ea l l l l l l Crossload l Cr ssjoad l i i l l l l l l l l Task Watchdogl l l l l l l Nme RN me 1NN me 15N me INN me IRN me 2NN me 2RN me In the event of a watchdog timeout a major fault type 6 code 1 results If this fault occurs after a switchover the control system fails to safe or to the configured hold state Figure 55 Watchdog Not Configured for Redundancy Switchover l Program 2 Program 3 l Switchover l l l l l l l l l Task l Crossload l I l l l l ae l l l l l l Crossload Cros joad l l l l l l l l l Task Watchdogl l D l l l l 0 ms 5
258. omation Publication 1756 UM535D EN P November 2012 123 Chapter6 Configure the Redundancy Modules Interpret an Event s Extended Information The information listed in this table can be provided depending on the type of event after you have accessed the Extended Information Definition dialog box Information Type Event Information Description The enhanced redundancy system assigns this event information Event number Date and time the event occurred Event classification Submitter Information This information reflects information specific to the module that reported the event Information provided in this section includes the Name of the module that originated the event e Slot number of the module that originated the event Serial number of the module that originated the event Event Details This section provides these additional details about the event e Description of the event e Examine the Extended Data Definition which provides an explanation of the event and bytes for errors Extended Data Bytes in Hexadecimal that provides further details the event Export Event Log Data After you have viewed extended information about an event you could need to export event data You can export data with either of these features e Export Selection e Export All Available with enhanced redundancy system Revision 19 052 or later Export Selection Use this feature to export event log d
259. on Deleted Starts 10373 3 24 2012 08 53 44 734 0 1756 L73 36 Partner Connection Closed State C 10372 3 24 2012 08 53 44 731 1 1756 AM2 19 Chassis Redundancy State changed to PwDS State C 10371 3 24 2012 08 53 44 729 2 1756 EN2T 1 Network Transition to Not Attached Synch 10370 3 24 2012 08 53 44 716 1 1756 AM2 C2 Bridge Connection Deleted Starts 10369 3424 2012 08 53 44 716 1 1756 AM2 C2 Bridge Connection Deleted Starts 10368 3 24 2012 08 53 44 7151 1756RAM2 C2 Bridge Connection Deleted Starts 10367 ete 2 08 53 44 71 1 1756 RM2 BD SYS_FAIL_L Active in Partner RM Failure 2 1756 aa F Partner Connection Closed 7N 1 M assis Redundancy State changed tu Rug 5 e TER 2 1756 TA 14 Enter Qualification Phase 4 Qualfic 10363 3 24 2012 08 44 48 8916 1 1756 AM2 2E Qualification Complete Qualific 1030 UIAM NAAA AV ATA 2 176R FNIT_ HA Fnter Nualifiration Phase 3 Aualifie lt Lili Module Into Configuration Synchronization Synchronization Status Event Log l System Update System Event History Auto Update Partner Log CON OFF C OPEN CLOSE Export Selection Export All Chassis B Log Time Slot Module Na Description Classific A 9945 3 24 2012 08 53 44 795 1 1756 RM2 C2 Bridge Connection Deleted Starts 9944 3 24 2012 08 53 44 775 1 1756 RM 2 C2 Bridge Connection Deleted Starts 9943 3 24 2012 08 53 44 755 1 1756 RM 2 C2 Bridge Connection Deleted Starts 9942 3 24 2012 08 53 44
260. on Publication 1756 UM535D EN P November 2012 Set the Task Watchdog Set the Redundancy Module Date and Time Program the Redundant Controller Chapter 7 To set the wallclock time of the 1756 RM module use the MSG instruction parameters listed in this table Table 33 Set Wallclock Time In this tab Configuration Edit this element To use this value Message Type CIP Generic Service Type Custom Service Code 10 Class 8b Instance 1 Attribute b Source Element WallClockTime 0 WallClockTime is a DINT 2 array that stores the CurrentValue of the WALLCLOCKTIME object Source Length 8 Destination Element None no value needed Communication Path Browse for the path to the 1756 RM or 1756 RMXT redundancy module Connected box Leave the Connected checkbox unchecked Watchdog times set for tasks in redundancy applications must be larger than watchdog times set for tasks in nonredundancy applications because more time is required to conduct crossloads and synchronization An increase in the required watchdog time is also a result of the way programs are executed in the event of a switchover A program or programs may be executed a second time after switchover depending on when in the task or program the switchover occurs and where in the task crossload and synchronization occurs Ifa program is executed a second time the length of time required for the pr
261. on page 100 4 Place the primary controller in Run mode 5 Apply power to the secondary chassis If the Auto Synchronization parameter is set to Always the system begins qualification and synchronization automatically 6 Ifyour Auto Synchronization parameter is set at Never or Conditional Disable use the synchronization commands in the Synchronization tab of the RMCT to qualify and synchronize your system For more information about using the synchronization commands in the 1756 RMCT module see Commands in the Synchronization Tab on page 117 You have completed the steps necessary to upgrade a standard system to an enhanced system IMPORTANT Before bringing your newly upgraded system online and into production mode test the system to verify that the changes made are suitable for your application Rockwell Automation Publication 1756 UM535D EN P November 2012 243 AppendixC Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Upgrade Ethernet Modules When Rotary Switches Are Set between 2 254 244 This section includes the procedure to upgrade your Ethernet communication modules when the modules rotary switches are set to 2 254 and you are unable to interrupt the primary IMPORTANT This procedure must be executed before steps 6 12 of Upgrade by Using Redundancy System Update on page 250 IMPORTANT This isa change from prior releases upgrade procedures
262. ondary partner QSwP Qualified synchronized secondary with primary partner DSwP Disqualified secondary with primary partner DSwNP Disqualified secondary with no partner PwDS Primary with disqualified secondary partner PwNS Primary with no secondary partner Export All Event Logs To export event logs with the RMCT version 8 01 05 follow these steps 1 Open the RMCT on the 1756 RM module in the primary chassis and click the Event Log tab 2 Click Export All meee nug Cerner g eymu meus g vyenu meaner wee So oe pre pe g Seer rein ree Auto Update p Partner Log P C ON C OFF OPEN CLOSE Export All Chassis B Event Log Time Si Module Na Description Classification 566391 7 19 2012 10 02 45 979 6 1756 AM 2 14 Chassis Redundancy State changed State Changes 566390 7 19 2012 10 02 45 860 0 1756 EN2TR 14 Enter Qualification Phase 4 Qualification 566389 7 19 2012 10 02 45 860 2 1756 EN2TR 14 Enter Qualification Phase 4 Qualification 566388 7 19 2012 10 02 45 839 6 1756 AM 2 2E Qualification Complete Qualification 566387 7 19 2012 10 02 45 759 0 1756 EN2TR 13 Enter Qualification Phase 3 Qualification 566386 7 19 2012 10 02 45 758 2 1756 EN2TR 13 Enter Qualification Phase 3 Qualification 566385 7 19 2012 10 02 42 984 2 1756 EN2TR 12 Enter Qualification Phase 2 Qualification FARRAR 7 19 2012 101 N 4 9R3 n 175R FN2TR 121 Fnter Qualification Phase 2 Qualification
263. onse to Open Bridge Connection Starts Stops 960707 11 16 2010 14 13 59 435 1756 RM Request to Open Bridge Connection Starts Stops 960706 11 16 2010 14 13 59 425 1756 AM 2 Response to Open Bridge Connection _Starts Stops 960705 11 16 2010 14 13 59 425 1756 EN2 Partner Connection Opened Synchronizati 960704 11 16 2010 14 13 59 424 1756 RM 2 Request to Open Bridge Connection Starts Stops 960703 11 16 2010 14 13 59 414 1756 RM 2 Response to Open Bridge Connection _Starts Stops zl Export Diagnostics Clear Fault Extended Info gt gt Unknown Redundancy Status Futo Synchronization State UnKnown Chassis Platform Configuration Unknown With this feature you can remotely restart the redundancy module without physically removing and reinserting it from the chassis The module restart clears the fault IMPORTANT Export all event and diagnostic data from the module before you clear major faults from the module Clear Fault is active only when the redundancy module is in a major faulted state Module faults are displayed on the Module Info tab This example graphic shows information for a module that has experienced a major fault Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History Redundancy Module Identification Status i MAJ FAULT Vendor Rockwell Automation Allen Generel Siete OR Bradley Major Fault None Product Type Redundancy
264. operating system Set aside connections for each PanelView Plus or VersaView CE terminal In this module Reserve Controller 5 connections 1756 CN2 B 1756 CN2R B 5 connections FactoryTalk View Supervisory Edition software with RSLinx Classic software version 2 52 or later RSView32 software Any other HMI client software that uses RSLinx Classic software version 2 52 or later Limit the number of RSLinx servers that a controller uses to 1 ideal to 3 maximum HMI connected to a primary chassis exclusively over a ControlNet network or bridge from an EtherNet IP network to a ControlNet network maintains its connections during a switchover Rockwell Automation Publication 1756 UM535D EN P November 2012 47 Chapter 2 48 Design an Enhanced Redundancy System ControlNet Connection from HMI Over a ControlNet Network shows an example of connecting an HMI to a primary controller over a ControlNet network Figure 11 Connection from HMI Over a ControlNet Network HMI O mara 1756 CN2R 1756 IB16D Redundant Chassis Pair 1756 EN2TR 1756 CN2R 1756 EN2TR 1756 CN2R For an example of how to connect an HMI to a redundant chassis pair over a path that bridges from an EtherNet IP network to a ControlNet network see Configuration Used to Eliminate Communication Delays on Switchover on page 37 Roc
265. or disqualify e Initiating a switchover e Forcing the disqualified secondary to become the primary The commands available are described in the Commands in the Synchronization Tab section on page 117 This tab also provides information about the last four synchronization attempts in the Recent Synchronization Attempts log Attempts are identified by N or N X If the redundant chassis fail to synchronize a cause is identified in the Recent Synchronization Attempts log The causes and their interpretations are described in the Recent Synchronization Attempts Log section on page 118 Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History Redundancy Commands Sinehnorize Second Disqualify Secondary Initiate Switchover Recent Synchronization Attempts Result Cause N Success N 1 N 2 N 3 Success Description Abort Module Pair Incompatible Abort Module Pair Incompatible Refresh Select an entry in the Recent Synchronization Attempt list to see Details 116 Rockwell Automation Publication 1756 UM535D EN P November 2012 Command Synchronize Secondary Configure the Redundancy Modules Chapter 6 Commands in the Synchronization Tab These sections explain each redundancy command and the system conditions that are required for the command to be available Description This command forces the primary redundancy module
266. ork e Produced and consumed tags use connections in both the controllers and the communication modules being used e Because the use of produced and consumed tags uses connections the number of connections available for other tasks such as the exchange of I O data is reduced The number of connections available in a system depends on controller type and network communication modules used Closely track the number of produced and consumed connections to leave as many as necessary for other system tasks 94 Rockwell Automation Publication 1756 UM535D EN P November 2012 Network Update Time Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the ControlNet Network Chapter 5 The network update time NUT that you specify for your redundant system impacts your system performance and your switchover response time Typical NUTs used with redundant systems range from 5 10 ms NUTs with Multiple ControlNet Networks You can choose to use multiple ControlNet networks with your enhanced redundancy system Figure 28 Example of Two ControlNet Networks il Digital Input Digital Input Digital Ouput Analog Input 1756 CN2R 1756 CN2R 1756 CN2R 1756 RM2 1756 CN2R ControlNet Network 1 NUT 5 ms ControlNet Network 2 NUT lt 21 ms 1756 CN2R Digital Input When you use multiple ControlNet networks the networks must use compatible NUTs
267. ors to display PRIM 3 Apply power to the chassis you want to designate as the secondary chassis 4 Verify primary and secondary chassis designations by viewing the module status display and the PRI indicator See Status Indicators on page 227 for specific redundancy module display information IMPORTANT __ If both modules have power applied to them simultaneously the module with the lowest IP address is designated as the primary chassis and displays PRIM on the module s four character display In addition the PRI status indicator on the primary redundancy module is green The secondary chassis displays either DISQ or SYNC depending on the state of the secondary chassis In addition the PRI status light on the secondary redundancy module is not illuminated Rockwell Automation Publication 1756 UM535D EN P November 2012 Install the Enhanced Redundancy System Chapter 3 After Designation When you first apply power to the designated primary and secondary chassis compatibility checks are carried out between the redundant chassis Then because the default Auto Synchronization parameter is set at Always qualification begins TIP While the qualification occurs the module status display transitions from DISQ disqualified to QFNG qualifying to SYNC synchronized The qualification s completes in 1 3 minutes and then module status display indicates the qualification status Use this table as a reference when interpreting t
268. ossload Figure 43 Tags in One User Defined Data Type My _Bools Bool_1 My_Bools Bool_2 My Bools Bool_3 My_Constants My_Constants Constant_1 My_Constants Constant_2 t My_Constants Cosntant_3 My_Reals M y_Reals Real_1 _Mu Reals Real 2 Tag Name amp Type ais My_Data_UDT My _Bools_UDT My_Data Constant_1 DINT BOOL My Data Constan 2 DINT BOOL H My_Data Cosntant_3 DINT BOOL My_Data Bool_1 BOOL My_Constants_UDT My_Data Bool_2 BOOL DINT My_Data Bool_3 BOOL DINT My_DataReal1 REAL DINT My Data Real_2 REAL My_Reals_UDT My Data Real_3 IREAL REAL REAL Use DINT Tags Instead of SINT or INT Tags when Possible We recommend that you use the DINT data type instead of the SINT or INT data types because the controller usually works with 32 bit values DINTs or REALs When processing the controller converts SINT or INT tag values to DINT or REAL values When processing is complete the controller converts the value back to a SINT or INT value The controller automatically converts these data types while executing and processing a program No additional programming is required However while this conversion process is transparent to you it does require additional processing time that impacts your program scan time and your switchover time Rockwell Automation Publication 1756
269. otal connections If you use the redundant controller at or very near the connection limits you can experience difficulty synchronizing your chassis Redundancy Modules in Redundant Chassis Two redundancy modules one in each chassis of the redundant chassis pair jointly supervise the control system operating states and transitions establishing the framework for system redundancy This bridge between chassis facilitates the exchange of control data and synchronization of operations The redundancy modules let you commission the redundant system in a plug and play manner without any programming You connect a redundancy module pair with the default configuration in the redundant chassis pair and set up the redundant system You can establish redundancy between chassis in either of these manners e Inserting a redundancy module pair into two powered chassis that contain redundancy compliant components and redundancy enabled application programs and then connecting the redundancy modules e Inserting and connecting the redundancy modules in two chassis and then inserting redundancy compliant components into each chassis IMPORTANT _Youare not required to develop any programming to migrate from a nonredundant to an enhanced redundancy system if your application meets these conditions e Your application meets the points listed in Restrictions on page 22 e The controller properties in your RSLogix 5000 software project has Redundan
270. oubleshoot a Redundant System Partner Network Connection lfa partner network connection between a redundant chassis pair is lost a state Lost change or switchover may occur These state changes may result e Primary with qualified secondary changes to primary with disqualified secondary e Qualified secondary with primary to disqualified secondary with primary To use the Event Log to determine if a lost partner network connection caused a state change complete these steps IMPORTANT This example shows a connection lost over a ControlNet network You same steps apply if the connection is lost over an EtherNet IP network 1 Open RSLinx Classic software and access the RMCT of the primary redundancy module This is the chassis that was previously the secondary but is now the primary Primary Chassis E A 192 168 1 41 1756 EN2T 1756 EN2T A Backplane 1756 44 4 00 1756 L73 LOGIX5573 NSONL_Example 02 1756 EN2T 1756 EN2T A 03 1756 RM2 4 1756 RM2 REDUNDANCY Mou o_O Secondary Chassis Be gt f 192 168 1 42 1756 EN2T 1756 ENZT A Remove Backplane 1756 A4 A Driver Diagnostics HP 00 1756 L73 LOGIXS573 NSONL_Example i R Configure Driver 02 1756 ENZT 1756 ENTIA Upload EDS file from device 03 1756 RM2 A 1756 RM2 REDUNDANCY MODULE P Security Device Properties Module Configuration k 2 Locate the last event that indicates successful qualification and status Primary Chassis C
271. ovember 2012 Status Indicators Appendix A Table 48 describes the alphanumeric codes The fault code is a four character alphanumeric string Valid characters are 0 9 and A through Z except S and O The first character is always E Each firmware subsystem within the redundancy module is assigned a range of fault codes Each subsystem assigns fault codes within its range Table 48 Alphanumeric Error Codes Valid Character String Indication E Error x The subsystem in which the error was detected x The subsystem function or group of functions in which the error was detected xX The specific error Range Subsystem Range Subsystem EO Back up Control Objet EC__ Object Communication El OS Board Support Package ED__ Wall Clock Time Object E2 Chassis Profile Object EE__ Non maskable Interrupt Service Routine E3222 Coordinated System Time Object EF__ Nonvolatile Storage Object E4__ Device Object EG__ RM Fault Handler ES Extended Log Object EH__ Self Test Object E6__ Event Log Object El__ Workstation Display Object E7 Back up Communication Object EJ__ Industrial Control Platform Object E8_ ICP Toolkit EK__ RM Watchdog Manager E9 Indicator Device Driver EL__ Instrumentation Object EA__ RM State Machine EM__ File Object EB Event Log Device Driver If you encounter one of these error codes record the Exxx code and contact Rockwell Automation Technical Support Recovery M
272. p your system for the first time 1 Install update the workstation software and firmware bundle Refer to Step 1 Install the Software on page 53 Software applications needed include e RSLogix 5000 software e RSLinx Classic communication software e Redundancy Module Configuration Tool RMCT See Install the Software on page 53 IMPORTANT __ If RSLinx Classic software is already on your system make sure to shut it down before installing upgrading software Rockwell Automation Publication 1756 UM535D EN P November 2012 51 Chapter 3 52 Install the Enhanced Redundancy System 2 To begin the hardware installation determine the location of your modules in the system s chassis Plug in the communication modules controller and redundancy modules into the chassis matching partners slot for slot See Step 2 Install the Hardware on page 54 Install the following e The first chassis and power supply see page 54 e The first chassis communication modules see page 56 a Determine the IP address for your Ethernet communication modules Each Ethernet communication module will have the same IP address Be sure to reserve the next Ethernet IP address in series for the secondary controller to use in the case of a switchover For example 192 105 1 5 and 192 105 1 6 b Set both Ethernet communication modules to the same IP address This rule also applies to ControlNet networks See Configure the EtherNet IP Netwo
273. pdates 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 www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its 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 follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how
274. r intervals that you specify Rockwell Automation Publication 1756 UM535D EN P November 2012 19 Chapter 1 20 About Enhanced Redundancy Systems Switchovers During redundant system operation if certain conditions occur on the primary chassis primary control is switched to the secondary chassis These conditions cause a switchover e Loss of power e Major fault on the controller e Removal or insertion of any module e Failure of any module e Damage toa ControlNet cable or tap This event only causes a switchover if it results in the ControlNet communication module transition to a lonely state that is the module does not see any devices on the network e Loss of an EtherNet IP connection This event only causes a switchover if it results in the EtherNet IP communication module transition to a lonely state that is the module does not see any devices on the network e A program prompted command to switchover e A command issued via the Redundancy Module Configuration Tool RMCT After a switchover occurs the new primary controller continues to execute programs beginning with the highest priority task that had been executing on the previous primary controller For more information about how tasks execute after a switchover see Crossloads Synchronization and Switchovers on page 144 Your application can require some programming considerations and potential changes to accommodate a switchover For more information on
275. r is unchecked IMPORTANT Do not use Match Project to Controller property with redundant controllers If you use the Match Project to Controller property available in the Advanced tab of the Controller Properties dialog box you cannot go online with download to or upload from the new primary controller after a switchover This is because the serial number of the new primary controller is not the same as the serial number of the old primary controller and the project cannot be matched to the newly switched to controller 142 Rockwell Automation Publication 1756 UM535D EN P November 2012 Verify this is not checked gt Program the Redundant Controller File Redundancy Nonvolatile Memory Memory Security General Major Faults Minor Faults Date Time Advanced SFC Execution Controller Fault Handler lt none gt v Power Up Handler lt none gt v System Overhead m Time Slice 20 j During unused System Overhead Time Slice Run Continuous Task O Reserve for System Tasks eg Communications Match Project to Controller Serial Number C llow Consumed Tags to Use RPI Provided by Producer E Chapter 7 You have completed the minimum configuration required for your redundant controllers Rockwell Automation Publication 1756 UM535D EN P November 2012 143 Chapter7 Program the Redundant Controller Crossloads Synchronization and Switchovers
276. ram Error Error in writing in NVS device while updating application image Cycle power to the redundancy module If the error persists replace the module CONFIG Erase Error Error in erasing NVS device while updating configuration log image Cycle power to the redundancy module If the error persists replace the module CONFIG Program Error Error in writing in NVS device while updating configuration log image Cycle power to the redundancy module If the error persists replace the module EEPROM Write Error Error in writing in EEPROM device while updating configuration log image Cycle power to the redundancy module If the error persists replace the module Application Update Required The module is running boot firmware Download the application firmware obtained from the respective redundancy bundle ICPT A test line on the backplane is asserted Check if the error message goes away after removing each module one at a time If error persists cycle power to the chassis or replace the chassis Cpt All modules in the chassis do not belong to the same standard or enhanced redundancy platform Rockwell Automation Publication 1756 UM535D EN P November 2012 231 AppendixA Status Indicators OK Status Indicators The OK status indicator reveals the current redundancy module state Table 44 OK Status Indicator Indicator State Off Description No power is applied to the redundancy module If necessary apply
277. re with RSLinx Enterprise software e Use RSLinx Enterprise communication software version 5 0 or later e Keep the HMI and both redundant chassis on the same subnet Configure the network to use IP swapping FactoryTalk View Supervisory Edition software with RSLinx Classic software version 2 52 or later e RSView 32 software Any other HMI client software that uses RSLinx Classic software version 2 52 or later Limit the number of RSLinx servers that a controller uses to 1 3 servers where the use of 1 server is ideal HMI connected to a redundant chassis pair exclusively over an EtherNet IP network can briefly drop the connection when a switchover occurs The connection is re established however after the switchover is complete Rockwell Automation Publication 1756 UM535D EN P November 2012 Design an Enhanced Redundancy System Chapter 2 HMI Connected via a ControlNet Network This table describes redundant system considerations specific to the HMI being used on the ControlNet network Type of HMI Used e PanelView Standard terminal e PanelView 1000e or PanelView 1400e terminal Considerations If your HMI communicates via unscheduled communication use four terminals per controller If your HMI does not communicate via unscheduled communication use the number of terminals required for your application e PanelView Plus terminal e VersaView industrial computer running a Windows CE
278. red in the secondary redundancy module the secondary chassis will disqualify and will not be able to take over control if the primary redundancy module fails Major Nonrecoverable This fault type results in these conditions This is a critical fault Redundancy operations will cease Aswitchover may occur No recover mechanism is available The module may need to be replaced When the redundancy module experiences a fault indication of that fault type is presented in these methods e Event log e Module Status Display IMPORTANT This section describes a subset of module fault codes you may see in the event log or Module Status Display If you see a fault code not included in this chapter contact Rockwell Automation for assistance in troubleshooting that fault Event Log When Redundancy Module Experiences Fault The redundancy module logs the fault type in its event log in NVS memory You access the event log through the RMCT to troubleshoot the fault yourself or with assistance from Rockwell Automation Technical Support for troubleshooting the fault Rockwell Automation Publication 1756 UM535D EN P November 2012 233 Appendix A 234 Status Indicators Module Status Display A character string scrolls across the Module Status Display to indicate the fault type The character string displays the fault type in either of these ways e Twoto four character word abbreviations e Alpha numeric codes This tabl
279. rk on page 77 e The first chassis controller see page 56 e The first chassis redundancy module see page 57 e The second chassis power supply communication modules controller and redundancy module See page 63 Plug in the fiber optic communication cable to connect the redundancy modules in both chassis See Step 3 Connect the Redundancy Modules via a Fiber optic Cable on page 63 Upgrade the redundant chassis firmware See Step 4 Update Redundant Chassis Firmware on page 67 e Update the firmware to the modules in the first chassis e Apply power to the first chassis e Launch ControlFLASH software and upgrade the firmware e Upgrade the redundancy module s firmware and verify that the status is PRIM e Update all remaining modules in the chassis using Control FLASH software e Power off the first chassis e Power on the second chassis e Follow the same update process as the first chassis e Power off the second chassis Designate the primary chassis See Step 5 Designate the Primary and Secondary Chassis on page 71 e Verify power is removed from both chassis e Apply power to the chassis you want designated as the primary Wait for the status indicator to display PRIM e Apply power to the chassis you want designated as the secondary Rockwell Automation Publication 1756 UM535D EN P November 2012 Install the Enhanced Redundancy System Chapter 3 Install an Enhanced The followi
280. roller is running an application that contains a feature qualified to run only on an enhanced redundant platform for example Alarms ICPT Asserted Atest line on the backplane is asserted Unicast Not Supported A unicast connection is configured in the redundant controller and enhanced redundancy systems do not support Unicast PTP Configuration Error Aredundant controller s PTP clock is not synchronized or the partner controller pair is synchronized to a different grandmaster Secured Module Mismatch Synchronization Status Tab A mismatch was detected between a primary and secondary secured module The Synchronization Status tab provides a module level view of these items e Synchronization state for example Synchronized or Disqualified e Chassis designation Primary or Secondary e Module compatibility with its partner for example Full or Undefined Each module installed in the chassis is identified and information regarding its partner and compatibility are provided Chassis Designation Module partner Compatibility Synchronization State Module Info Configuration Synchronization Synchronization Status Event Slot Complete Module Name System Event Module Revision Secondary Readiness State Compatibility 0 100 1756 L73 4 LOGIX5573 19 53 Synchronized Primary Full 1 lt empty gt 2 100 1756 EN2T 7A 5 8 Synchronized Primary Full 3 100 1756 AM2 REDUNDANCY 20 4 Synchroni
281. rollers if applicable Once you have upgraded the firmware for each of the modules in the new secondary chassis continue by synchronizing the redundant chassis Rockwell Automation Publication 1756 UM535D EN P November 2012 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C Step 12 Synchronize the Redundant Chassis Complete these steps to synchronize the redundant chassis after firmware in both chassis have been upgraded to the same revision 1 Launch the RMCT for the redundancy module in the primary chassis by right clicking on the module in RSLinx Classic software and selecting Module Configuration 4 192 168 1 41 1756 EN2T 1756 EN2T 4 amp Backplane 1756 A4 4 f 00 1756 L73 LOGIX5573 NSONL_Example 02 1756 EN2T 1756 EN2T 4 03 1756 RM2 4 1756 RM2 REDUNDANCY MODUL f 192 168 1 42 1756 EN2T 1756 EN2T A Remove 6 Backplane 1756 44 4 00 1756 L73 LOGIX5573 NSONL_Example 02 1756 EN2T 1756 EN2T A4 03 1756 RM2 4 1756 RM2 REDUNDANCY MODULE Driver Diagnostics Configure Driver Upload EDS file from device Security Device Properties Module Configuration 2 From the Auto Synchronization pull down menu choose the frequency that suits your application m Redundancy Module Options Auto Synchronization Chassis ID Qe Click Apply then click Yes 4 Synchronize the chassis Redundancy Commands stills Secondary
282. rror out with Error 1 Extended Error 301 No Buffer Memory Rockwell Automation Publication 1756 UM535D EN P November 2012 173 Chapter7 Program the Redundant Controller 174 Disqualify the Secondary Chassis To disqualify the secondary chassis use the MSG instruction parameters listed in this table Table 31 Disqualify the Secondary Chassis In this tab Edit this element To use this value Configuration Message Type CIP Generic Service Type Custom Service Code 4d Class bf Instance 1 Attribute None no value needed Source Element INT tag with a value of 1 Source Length 2 Destination Element None no value needed Communication Path Browse for the path to the 1756 RM or 1756 RMXT redundancy module Connected box Leave the Connected checkbox unchecked Synchronize the Secondary Chassis To disqualify the secondary controller use the MSG instruction parameters listed in this table Table 32 Synchronize the Secondary Chassis In this tab Edit this element To use this value Configuration Message Type CIP Generic Service Type Custom Service Code Ac Class bf Instance 1 Attribute None no value needed Source Element INT tag with a value of 1 Source Length 2 Destination Element None no value needed Communication Path Browse for the path to the 1756 RM or 1756 RMXT redundancy module Connected box Leave the Connected checkbox unchecked Rockwell Automati
283. s Redundant System Before You Begin Before you begin configuring the EtherNet IP communication modules in the redundant chassis verify that these tasks have been completed e The redundancy modules are installed and connected in the redundant chassis e A plan for IP address use has been executed Ifyou are using IP address swapping plan for the use of two consecutive IP addresses in the partnered set Ifyou are not using IP address swapping plan for the use of two IP addresses e Know the subnet mask and gateway address for the Ethernet network the redundant modules are to operate on Rockwell Automation Publication 1756 UM535D EN P November 2012 85 Chapter 4 86 Configure the EtherNet IP Network Options for Setting the IP Addresses of EtherNet IP Communication Modules By default ControlLogix EtherNet IP communication modules ship with the IP address set to 999 and with Bootstrap Protocol BOOTP Dynamic Host Configuration Protocol DHCP enabled Use one of these tools to set the IP addresses for your EtherNet IP communication modules e Rotary switches on the module e RSLinx Classic communication software e RSLogix 5000 software e BOOTP DHCP utility Provided with RSLogix 5000 software Half Full Duplex Settings The enhanced redundancy system uses the duplex settings of the EtherNet IP communication module that is currently the primary After a switchover the duplex settings of the new primary E
284. s With firmware revisions 16 081 and earlier an EtherNet IP network does not support 1 0 or produced consumed tags Enhanced redundancy systems support unicast produced tags Unicast consumed tags are not supported in enhanced redundancy systems USB ports of communication modules in the redundant chassis are not used while the system is running online IP addresses of devices on the EtherNet IP network are static and IP address swapping is enabled 280 Rockwell Automation Publication 1756 UM535D EN P November 2012 Enhanced Redundancy System Checklists Appendix F v Requirement EtherNet IP HMI HMI Blind Time is the time during a switchover from primary to secondary when tag data from the controller is unavailable for reading or writing See HMI Blind Time Reduction on Ethernet During a Switchover on page 21 IMPORTANT This feature requires RSLinx Enterprise software version 5 50 04 or later e PanelView Standard terminal None the use of the PanelView Standard terminal in a redundant system requires the same considerations as a nonredundant system PanelView Plus terminal VersaView industrial computer running a Windows CE operating system RSLinx Enterprise software version 3 0 or later is used Within each of the controllers and communication modules five connections for each PanelView Plus or VersaView terminal are reserved FactoryTalk View SE software with RSLinx Enterprise software RSLinx Ent
285. s your system begins synchronizing immediately after the switchover PS aaa Module Info Configuration Synchronization Synchroni Redundancy Module Options Auto Synchronization To monitor the synchronization of your system after you initiate the test switchover you can monitor the synchronization process by using these methods e Click the Synchronization Status tab and monitor the Secondary Readiness column The states No Partner Disqualified Synchronizing and Synchronized indicate the stages of synchronization e View the module status display of a primary communication module The states PWNS PsDS PwQg and PwQS indicate the stages of synchronization e View the module status display of the secondary redundancy module The states DISQ QFNG and SYNC indicate the stages of synchronization 196 Rockwell Automation Publication 1756 UM535D EN P November 2012 Monitor and Maintain an Enhanced Redundancy System Chapter 8 Check the ControlNet Module After you have programmed your redundant system and configured your ControlNet network check two statistics specific to your ControlNet modules These statistics include the CPU usage and the connections used Status To view the CPU usage and the number of connections used complete these steps 1 In RSLinx Classic software open the Module Statistics for the ControlNet module A ControlNet 06 1756 CNBR E 1756 CNBR E 11 003 09
286. s is often referred to as HMI Blind Time Beginning with version 20 054 HMI Blind Time due to switchover has been reduced IMPORTANT _ RSLinx Enterprise software version 5 50 04 CPR9 SR5 is required beginning with version 20 054 HMI Blind Time is dependent on several system variables that determine this length of time as follows e Quantity and types of tags on scan in RSLinx Enterprise software e Client screen update rates e Number of program and controller scope tags in the redundant controller e Controller loading which includes the following e Number of tasks and scan rates assumes no continuous task e Memory usage e Null task percentage available e Network traffic Based on testing with Windows Server 2003 software HMI Blind Time was reduced between 40 80 User results will vary based on the variables listed above IMPORTANT _ RSLinx Enterprise software is part of FactoryTalk Services which has been releasing a series of Service Releases SRs that are backward compatible with any CPR 9 products The HMI Blind Time feature can be used by existing and new users who are using FactoryTalk View version 5 0 CPR9 or newer Rockwell Automation Publication 1756 UM535D EN P November 2012 21 Chapter1 About Enhanced Redundancy Systems Restrictions There are restrictions that you must consider when using an enhanced redundancy system Most of these restrictions apply to all enhanced redundancy system revis
287. s anomaly with the redundancy system Command An event related to commands issued to the redundant system has No corrective action is required occurred This event is provided for informational purposes and does not indicate For example if you change the Redundancy Module Date and Time serious anomaly with the redundancy system parameters a WCT time change event of the Command classification is logged Failure A failure on the redundancy module has occurred Action can be required to determine the cause of the failure For example an internal Firmware error event classified as a Failure can If the failure is not followed by a Switchover or Major Fault event then the be indicated in the event log module could have corrected the error internally and additional action is not required To determine if corrective action is required double click the event to see Extended Event Information and the suggested recovery method if applicable Major Fault A major fault has occurred on one of the redundancy modules Action can be required to determine the action needed to correct the fault Double click the event to see Extended Event Information and the suggested recovery method if applicable Minor Fault A minor fault has occurred on one of the redundancy modules No corrective action is required This event is provided for informational purposes and does not indicates serious anomaly with the redundancy system Starts Stops Various internal chassis
288. s compatible with If using a version earlier than 20 054 go to the Tech Support website at http www rockwellautomation support com to determine which RMCT version is required for use with your redundancy module firmware revision To find the latest firmware bundle on the website follow these steps 1 Once on the site choose Control Hardware 2 On the Firmware Updates page choose the latest firmware bundle 3 Download if different from your current module s firmware Complete these steps to check or verify the version of the Redundancy Module Configuration Tool RMCT that you have installed TIP The RMCT launches at the version that is compatible with the 1756 redundancy module firmware that is currently installed If you have not updated your 1756 redundancy module firmware after upgrading your RMCT version the RMCT version that is indicated may not reflect the version you updated to You can also check the RMCT version that you have installed by using Add or Remove Programs in the Control Panel 1 Launch RSLinx Classic software 2 Click the RSWho icon l 3 Right click your redundancy module and choose Module Configuration 4 192 168 1 41 1756 EN2T 1756 EN2T 4 amp Backplane 1756 44 4 00 1756 L73 LOGIXSS73 NSONL_Example 02 1756 EN2T 1756 EN2T A 03 1756 RM2 4 1756 RM2 REDUNDANCY MOD f 192 168 1 42 1756 EN2T 1756 EN2T A Remove amp Backplane 1756 44 4 j 00 1756 L73 LOGIX5573
289. s for DLR networks of 50 or fewer nodes e Support for CIP Sync technology e Two ports to connect to DLR networks in a single subnet Devices on a DLR network can function on the network in these required roles e Supervisor Nodes There are two types of supervisor nodes 1 Active Supervisor Node The network requires one active supervisor node per DLR network that executes these tasks Verifies ring integrity Reconfigures the ring to recover from a single fault Collects ring diagnostic information Rockwell Automation Publication 1756 UM535D EN P November 2012 87 Chapter4 Configure the EtherNet IP Network 2 Back up Supervisor Node An optional node that behaves like a ring node unless the active supervisor node cannot execute required tasks At that point the back up node becomes the active supervisor node e Ring Node A node that processes data transmitted over the network or passes the data to the next node on the network When a fault occurs on the DLR network these nodes reconfigure themselves relearn the network topology and can report fault locations to the active ring supervisor We recommend that you configure at least one back up supervisor node on the DLR network During normal network operation an active ring supervisor uses beacon and other DLR protocol frames to monitor network health Back up supervisor and ring nodes monitor beacon frames to track ring transitions between Normal and Faulted states
290. s graphic shows an example of an operating DLR network that includes an enhanced redundancy system Figure 24 Enhanced Redundancy System in a DLR Network Bi E FactoryTalk Application ore ae Cisco Switch T EH ee PEH fyy Stratix 8000 Switches Redundant Chassis Pair HMI Connected via i 1783 ETAP Taps Remote ControlLogix Chassis with Redundant Power 1715 Redundant 1 0 System Supplies and 1 0 Modules Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the EtherNet IP Network Chapter 4 Complete these steps to construct and configure the example DLR network 1 Install and connect devices on the DLR network but leave at least one connection open IMPORTANT When you initially install and connect devices on the DLR network leave at least one connection open that is temporarily omit the physical connection between two nodes on the DLR network You must configure an active supervisor node for the network before network operation begins when the final connection is made If you fully connect your DLR network without a supervisor configured a network storm can result rendering the network unusable until one link is disconnected and at least one supervisor is enabled This graphic shows the DLR network with one connection left open Figure 25 DLR Topology with One Connection Unmade i G la a FactoryTalk Application Cisco Switch E E at Pn Stratix 8000 Switches
291. set the Redundancy Module There are two ways to reset the module e Cycle power to the chassis e Remove the module from the chassis and reinsert the module IMPORTANT Only choose to cycle power to the chassis if you will not lose control of your process Remove or Replace the Redundancy Module To remove or replace the redundancy module follow these steps 1 Push on upper and lower module tabs to disengage them 2 Slide the module out of the chassis IMPORTANT If you want to resume system operation with an identical module you must install the new module in the same slot Rockwell Automation Publication 1756 UM535D EN P November 2012 75 Chapter3 Install the Enhanced Redundancy System Notes 76 Rockwell Automation Publication 1756 UM535D EN P November 2012 Chapter 4 Configure the EtherNet IP Network Topic Page Requested Packet Interval 77 Use IP Address Swapping 77 Use CIP Sync 81 Use Produce Consume Connections 84 Configure EtherNet IP Communication Modules in a Redundant System 85 Use An Enhanced Redundancy System in a Device level Ring Topology 87 Requested Packet Interval When using revisions earlier than 20 054 the RPI for I O connections in a redundancy enabled controller tree must be less than or equal to 375 ms When using revision 20 054 or later the RPI can be the same as a non redundant chassis CPU Usage The System Resource Utilization table describes CPU usage for EtherN
292. sic software 2 Click RSWho 3 Right click your redundancy module and choose Module Configuration 192 168 1 41 1756 EN2T 1756 EN2T A amp Backplane 1756 A4 4 00 1756 L73 LOGIX5573 NSONL_Example 02 1756 EN2T 1756 EN2T A 03 1756 RM2 4 1756 RM2 REDUNDANCY MODUL 5 192 168 1 42 1756 EN2T 1756 EN2T A Remove amp Backplane 1756 A4 4 Driver Diagnostics 00 1756 L73 LOGIX5573 NSONL_Example Configure Driver 756 T 1756 T A 0e ISS ENAT A756 ENET Upload EDS file From device 03 1756 RM2 4 1756 RM2 REDUNDANCY MODULE Security Device Properties Nose conaran a 252 Rockwell Automation Publication 1756 UM535D EN P November 2012 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C The Module Configuration dialog box opens 4 Right click the title bar and select About Restore Module Info Configuration Synchronization S Move Redundancy Module Identification size Minimize Vendor Rockwell Automation m maximize Bradley Product Type Redundancy Product x Close Alt F4 Product Code The About dialog box opens and indicates the RMCT version About Redundancy Configuration Tool _ Redundancy Configuration Tool Version 8 1 2 0 Copyright c 2011 Rockwell Automation Technologies Inc All Rights Reserved TIP The RMCT launches at the version that is compatible with the redundan
293. signature of all zeros TIP To clear the keeper signature of a 1756 CN2 1756 CN2R or 1756 CN2RXT module complete these steps 1 Disconnect the module from the ControlNet network and remove it from the chassis 2 Set the node address switches to 00 3 Insert the module back into the chassis and wait for the status display to indicate Reset Complete 4 Remove the module and set the node address switches to the intended node address 5 Insert the module into the chassis After being inserted and connected to the ControlNet network the unconfigured 1756 CN2 1756 CN2R and 1756 CN2RXT modules crossload the appropriate configuration from the active keeper on the ControlNet network and become configured with the appropriate keeper signature Rockwell Automation Publication 1756 UM535D EN P November 2012 103 Chapter5 Configure the ControlNet Network Notes 104 Rockwell Automation Publication 1756 UM535D EN P November 2012 About the Redundancy Module Configuration Tool RMCT Chapter 6 Configure the Redundancy Modules Topic Page About the Redundancy Module Configuration Tool RMCT 105 Determine if Further Configuration is Required 106 Use the RMCT 107 Module Info Tab 111 Configuration Tab 113 Synchronization Tab 116 Synchronization Status Tab 119 Event Log Tab 120 System Update Tab 130 System Event History 136 Using Dual Fiber Ports with the 1756 RM2 A Redundancy Module 138
294. sis 240 Rockwell Automation Publication 1756 UM535D EN P November 2012 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C Upgrade the System Software Upgrading your system software requires you to make many considerations and decisions Make sure you are fully aware of how your specific application will be affected when you upgrade system software e Ifyou are upgrading to enhanced redundancy system revision 16 081 or earlier you are not required to upgrade any software e Ifyou are upgrading to enhanced redundancy system revision 19 052 or later you must upgrade this software RSLogix 5000 software RSLinx Enterprise communication software or RSLinx Classic communication software depending on which RSLinx software you are using in the application Due to potential changes to your application when upgrading to enhanced redundancy system you may need to install any of the this software e FactoryTalk Alarms and Events e FactoryTalk Batch e RSNetWorx for ControlNet e RSNetWorx for EtherNet IP Upgrade the Controllers You may need to upgrade your controllers when upgrading to an enhanced redundancy system This table describes which controllers are available for system upgrades Controllers Available in Standard Redundancy Systems 1756 L61 1756 L62 1756 L63 1756 L64 Controllers Available in Enhanced Redundancy Systems All revisions 1756 L61 1756
295. sis 63 software 53 installation instructions 62 Index IP address 52 BOOTP DHCP utility 86 consecutive 78 plan 85 RSLinx communication software 86 RSLogix 5000 software 86 set 86 swap 78 swapping 36 77 79 switches 86 K keeper crossloads 102 status 101 mismatch 219 module status display 217 RSNetWorx for ControlNet software 217 unconfigured 218 valid 218 troubleshoot 216 L laser radiation ports 60 log Recent Synchronization Attempts 117 System Event History 136 logic scan dependent 160 M memory usage slider 185 1756 L7x 185 mode switch REM 68 Module Info tab 111 112 module placement chassis 54 module status display 192 monitor ControlNet sample programs 198 motion unsupported feature 17 MSG instruction 173 multicast 1 0 278 network 97 ControlNet monitor CPU usage 198 overview 38 Data Highway Plus 43 device level ring 35 87 DeviceNet 42 43 EtherNet IP 42 Rockwell Automation Publication 1756 UM535D EN P November 2012 289 Index 290 overview 35 37 keeper 101 keeper crossload 102 Remote 1 0 42 schedule existing 100 new 98 Universal Remote 1 0 43 update time 95 network update time 95 nonredundant controller 225 nonredundant to redundant conversion 73 nonredundant convert from 265 271 0 online edits 182 188 finalize 186 reserve memory 187 retain edits 184 test edits 183 operations chassis designation 19 crossload 19 enhanced redundancy system 19 q
296. sis or human machine interfaces HMIs For more information about components you can use in an enhanced redundancy system see Chapter 2 Design an Enhanced Redundancy System on page 23 Rockwell Automation Publication 1756 UM535D EN P November 2012 17 Chapter1 About Enhanced Redundancy Systems Remote 1 0 Module Placement EtherNet IP 1 0 network 1 0 Modules in Enhanced Redundancy Systems In an enhanced redundancy system you can use only I O modules in a remote chassis You cannot use I O modules in the redundant chassis pair This table describes differences in network use for I O in enhanced redundancy systems Available with Enhanced System Revision 19 052 19 053 or 20 054 Available with Enhanced System Revision 16 081 or Earlier 1715 Redundant 1 0 System ControlNet network DeviceNet network Data Highway Plus A SL PAS Universal Remote 1 0 v SIS AA 1 In an enhanced redundancy system you can access remote 1 0 modules on this network only via a ControlNet or EtherNet IP network bridge 18 For more information on using remote and 1715 redundant I O over an EtherNet network see I O Placement on page 44 and the Redundant I O System User Manual publication 1715 UM001 Rockwell Automation Publication 1756 UM535D EN P November 2012 Enhanced Redundancy System Operations About Enhanced Redundancy Systems Chapter 1 Once the redundancy modules in t
297. ss swapping If you are using different subnets you are responsible for programming your system to use the address and subnet of the new primary chassis in the event of a switchover Use IP Address Swapping If you use IP address swapping assign the same values for these configuration parameters on both EtherNet IP communication modules in the partnered set e IP address e Subnet mask e Gateway address This graphic shows a partnered set of EtherNet IP communication modules during initial configuration Figure 17 EtherNet IP Communication Modules IP Addresses During System Configuration Assigned IP Address 192 168 1 3 Primary chassis Secondary Chassis eS a a TE el a momo _ mi jo cz iia __ m om jc eaa Sse ay 890 220 s57 m N N oc LoS Si Lleol SHAE HOS gt 2 z 2 cof_ 2 i como I Lo LO de LO Lo co co N LO HI N LO LO o 78 Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the EtherNet IP Network Chapter 4 When an enhanced redundancy system begins operating the primary EtherNet IP communication module uses the IP address assigned during initial configuration The secondary EtherNet IP communicatio
298. ssis power or communication will halt the exporting process Switchover during export will result in aborting the exporting process PITT Abort 9 Ifyou want to export the secondary redundancy module log for a complete system view complete step 1 step 8 IMPORTANT Ifyou are exporting event data to provide to Rockwell Automation Technical Support to troubleshoot an anomaly you must obtain the event logs for both the primary and secondary redundancy modules Rockwell Automation Technical Support needs before logs to effectively troubleshoot the anomaly If you cannot access the secondary redundancy module s event log export it from the partner event log via the primary redundancy module Keep in mind though that the primary redundancy module s view of the secondary redundancy module s event log is typically limited To troubleshoot an anomaly with Rockwell Automation Technical Support you must obtain the secondary redundancy module s event log from the module s view itself Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Redundancy Modules Chapter 6 Export All Use this feature to automatically export all the available event log data for events in both of the redundancy modules of the redundant chassis pair We recommend that you use this feature when troubleshooting system related anomalies where the location of a fault could have occurred a lengthy period of time before the current e
299. st Prim_Chassis_ID_Last 0 If the Switchover_Occurred bit is on then the instructions added to this rung are executed and the Switchover_Occurred bit is reset a Switchover_Occurred TTT TBO OD OD Add your switchover dependent instructions here 170 Rockwell Automation Publication 1756 UM535D EN P November 2012 Program the Redundant Controller Chapter 7 Use Messages for me a applications you a ene to popan the e to issue edundancy Commands redundancy system commands via the redundancy modules The sections that R follow explain how to configure a MSG instruction to issue a redundancy command Verify User Program Control For a MSG instruction to issue a command via the redundancy modules the redundancy modules must be configured for user program control To verify that the modules are enabled for user program control access the Configuration tab of the RMCT and verify that Enable User Program Control is checked Figure 53 Enable User Program Control in the RMCT Module Info Configuration Synchronization Synchroni Redundancy Module Options Auto Synchronization Chassis ID Chassis A gt gt V Enable User Program Control Use an Unconnected Message When you add your MSG instruction that is to be used for issuing the command through the redundancy modules configure it as an unconnected message Message Configuration MSG_1 Configuration Communication Tag
300. stall configure program operate and troubleshoot a Redundant 1 0 system ControlLogix Controllers User Manual publication 1756 UM001 Contains information on how to install configure program and operate a ControlLogix system Logix5000 Controllers General Instructions Reference Manual publication 1756 RM003 Contains information on RSLogix 5000 programming instructions Logix5000 Controllers Quick Start publication 1756 QS001 Provides detailed information about how to use ControlLogix controllers ControlFLASH Firmware Upgrade Kit Quick Start publication 1756 05105 Contains information on how to upgrade module firmware Industrial Automation Wiring and Grounding Guidelines publication Provides general guidelines for installing a Rockwell Automation industrial system 1770 4 1 Product Certifications website http www ab com Provides declarations of conformity certificates and other certification details Rockwell Automation Publication 1756 UM535D EN P November 2012 13 Preface The following publications provide specific information about communication module connections Table 3 Additional Documentation Resources 1756 Communication Modules Specifications Technical Data publication 1756 TD003 Description Describes Ethernet communication module specifications ControlNet Modules in Logix5000 Control Systems User Manual publication CNET UM001 Describes ControlNet modules and how to use
301. stem Update System Event History Auto Update Partner Log ON OFF C OPEN CLOSE Export Selection Export All Chassis amp PwDS and end date and end time in Chassis A This is the time the redundancy module experienced a disqualifying event or switchover Event Log Time Slot Module Na Description Classific 10375 3 24 2012 08 53 44 735 0 1756 L73 36 Partner Connection Closed State C 10374 3 24 2012 08 53 44 735 1 1756 RM2 C2 Bridge Connection Deleted Starts 10373 HATH ai 0 1756 L73 36 Partner Connection Closed O State C 19 Chassis Redundancy State changed te PwDS 3 24720T2T yo 2 1756 EN2T 1 Network Transition to Not Attached Synch 10370 3 24 2012 08 53 44 716 1 1756 AM2 C2 Bridge Connection Deleted Starts 10369 3 24 2012 08 53 44 716 1 1756 AM2 C2 Bridge Connection Deleted Starts 10368 3 24 2012 08 53 44 715 9 1 1756 AM2 C2 Bridge Connection Deleted Starts 10367 3 24 2012 08 53 44 714 1 1756 AM2 BD SYS_FAIL_L Active in Partner RM Failure 10366 3 24 2012 08 53 44 714 1756 EN2T F Partner Connection Closed State C 10365 3 24 2012 08 44 48 952 1 1756 RM2 14 Chassis Redundancy State changed to PwOS State C 10364 3 24 2012 08 44 48 831 2 1756 EN2T 14 Enter Qualification Phase 4 Qualific 10363 3 24 2012 08 44 48 816 1 1756 AM2 2E Qualification Complete Qualific 1032F VIAIIMINAAAAPATA 2 APAR FN T 12 Fnter Nualifiratinn Phase 2 M ii v lt Pr
302. switchover change the redundancy module time or conduct synchronization then you must check Enable User Program Control in the Configuration tab If you leave Enable User Program Control unchecked the redundancy modules do not accept any commands from the controller Redundancy Module Date and Time The Redundancy Module Date and Time parameters can be applied separate from the Redundancy Module Options parameters The time specified with these parameters is the time referenced by the event logs when a redundant system event occurs To make changes to the redundancy module time settings use the pull down menu or type your changes then click Set to implement time changes Or to set the redundancy module s time to match that of the workstation click Apply Workstation Time IMPORTANT We recommend that you set the redundancy module date and time when you commission a system We also recommend that you periodically check the date and time settings to make sure they match those of the controller If a power failure occurs on the redundant chassis you must reset the date and time information of the redundancy modules The modules do not retain those parameters when power is lost Rockwell Automation Publication 1756 UM535D EN P November 2012 115 Chapter6 Configure the Redundancy Modules Synchronization Tab The Synchronization Tab provides commands for these options e Changing the synchronization state of the system synchronize
303. system operate by using the same program You do not need to create a project for each controller in the redundant system To configure your controllers to operate in a redundant system complete these steps 1 Open or create a RSLogix 5000 project for your redundant controller 2 Access the Controller Properties dialog box for the controller 3 8 Yo Configuration amp 1756 Backplane 1756 44 1h S f 2 1756 EN2T EN Sly Ethernet f 1756 EN2 S 1756 EN2 1756 f 8 0 8 2 ascription ajor Fault nor Fault Properties N Alt Enter Print Rockwell Automation Publication 1756 UM535D EN P November 2012 F 141 Chapter7 Program the Redundant Controller 3 Click the redundancy tab and check Redundancy Enabled General Major Faults Minor Faults Date Time Advanced SFC Execution File Redundancy Nonvolatile Memory I Memory Security Redundancy Enabled 4 Ifyou are going to complete edits to your redundant controller while online see these sections for information about the parameters available in the Advanced settings e Plan for Test Edits on page 183 e Reserve Memory for Tags and Logic on page 187 5 Click the Advanced tab J UGGI mou 1 aune mm une va nS suvanvcu Je LAGUI File Redundancy Nonvolatile Memory Memory Security Redundancy Enabled C Advanced gt Redundancy Status 6 Verify that Match Project to Controlle
304. t Controller Chapter 7 It is important to plan for controller crossloads because the length of the crossloads affects the scan time of your program A crossload is a transfer of data from the primary controller to the secondary controller and may occur at the end of each program or at the end of the last program in a task The scan time of your program or phase is a total of the program execution time and the crossload time The diagram below demonstrates this concept Figure 38 Crossload and Scan Time Crossload 4 Program Scan Time p Estimate the Crossload Time The amount of time required for a crossload is primarily dependent upon the amount of data being crossloaded During a crossload any tag that has been written to during the program execution is crossloaded Even ifa tag has not changed but has been rewritten during the program execution it will be crossloaded In addition to the time required to transfer tag value changes the crossload also requires a small amount of overhead time to communicate information about the program being executed Rockwell Automation Publication 1756 UM535D EN P November 2012 149 Chapter 7 150 Program the Redundant Controller Redundancy Object Attributes for Crossload Times Before you complete calculations to estimate the crossload time you need to use a Get System Value GSV instruction to read certain attributes of the redundancy object These attributes are data tra
305. t will stop functioning For detail information see Convert from a Nonredundant System on page 265 Rockwell Automation Publication 1756 UM535D EN P November 2012 73 Chapter3 Install the Enhanced Redundancy System Qualification Status via the RMCT To view the qualification attempt access the Synchronization or Synchronization Status tabs of the RMCT These tabs provide information about qualification attempts and redundant chassis compatibility For more information about using the RMCT see Chapter 6 Configure the Redundancy Modules on page 105 Figure 14 RMCT Synchronization Status Tab we 1756 RM B REDUNDANCY MODULE Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History Redundancy Commands Synchronize Secondary Disqualify Secondary Initiate Switchover Become Primary Recent Synchronization Attempts Success Abort Module Pair Incompatible Abort Module Pair Incompatible Success Figure 15 Synchronization Status Tab for Chassis Compatibility Chassis A Primary with Synchronized Secondary Futo Synchronization State Aways In addition you can view events specific to qualification in the Event Log of the RMCT Figure 16 Event Log with Qualification Events Chassis A 74 Rockwell Automation Publication 1756 UM535D EN P November 2012 Install the Enhanced Redundancy System Chapter 3 Re
306. t1 49 Use newest version of RMCT when using 1756 RM2 A redundancy module 54 Added the 1756 RM2 A and 1756 RM2XT modules and installation requirements 57 Added the statement 1756 RM2 A or 1756 RM2XT modules can only be used with 57 other 1756 RM2 A or 1756 RM2XT modules You cannot mix 1756 RM2 A and 1756 RM2XT modules with 1756 RM A 1756 RM B or 1756 RMXT modules Environment and Enclosure change 58 Small form factor pluggable warning 59 Added new 1756 RM2 A and 1756 RM2XT module graphics 61 Added installation instructions 62 Added information about connecting fiber optic cable to redundancy channels and 64 using redundant fiber cabling Updated fiber optic cable information for new redundancy modules 67 Updated the graphics for the redundant fiber optic cable 68 Updated the graphics for the redundant fiber optic cable 69 Using dual fiber ports with the 1756 RM2 redundancy modules 138 Crossload times when using a 1756 L7x and a 1756 RM2 A redundancy module 151 Using a 1756 L7x controller with a 1756 RM2 A redundancy module 152 Status indicators for 1756 RM2 A and 1756 RM2XT 200 1756 RM2 A and 1756 RM2XT status indicators 227 CH1 status indicator 229 CH2 status indicator 229 Rockwell Automation Publication 1756 UM535D EN P November 2012 3 Summary of Changes Table 1 New and Updated Information Topic Page SFP error message 230 Added missing Module Status Display
307. tarts Stops Starts Stops p Export Diagnostics Clear Faul Extended Info Chassis Platform Configuration Enhanced OK bey Hep Rockwell Automation Publication 1756 UM535D EN P November 2012 Troubleshoot a Redundant System Chapter 9 The Export Diagnostics dialog box appears asking you to continue specifying a communication path Export Diagnostics This process will be completed in few seconds You will need to specify the communications path to the partner RM Do you want to continue i This command will collect diagnostic data from both RMs of the redundant chassis pair 3 Click OK to specify the communication path via RSWho software The RSWho window appears Autobrowse i 2o Browsing node 3 found Ej Workstation USMAYSAMILLSO3 H Linx Gateways Ethernet gs 1784 PCIDS 1 DeviceNet E AB_ETHIP 1 Ethernet E 10 88 95 7 1769 L18ERM BB1B CompactLogix Processor 1769 L18ERM A LOGIXS318ERM 192 168 1 20 Unrecognized Device 1769 L18ERM A 5j 192 168 1 41 1756 EN2T 1756 EN2T A H 6 Backplane 1756 44 A Ej 00 1756 L73 LOGIX5573 Redundancy_update 02 1756 EN2T 1756 EN2T A 03 1756 RM2 A 1756 RM2 REDUNDANCY MODULE Ef 192 168 1 42 1756 EN2T 1756 EN2T A H E Backplane 1756 A4 A El 00 1756 L73 LOGIX5573 Redundancy_update 02 1756 EN2T 1756 EN2T A 03 1756 RM2 A 1756 RM2 REDUNDANCY MODULE Address Device Type f oo 1756 L73 LOGIX5573 f 02 1756 EN2T fj o3 1756 RM2 A 4 Select the commun
308. tchovers 00 000 144 Changing Crossload and Synchronization Settings 144 Default Crossload and Synchronization Settings 145 Recommended Task Types 0 25 teu ch ech cs waa ee ve enen 145 Continuous Task After Switchover lt 3 ic3 c 0 bo25 lt oreeutanutes 145 Multiple Periodic Packs ic aicn50 concened cag heey aes aokneee 147 Crossloads and Scan Tinie cc0teeig di aie ee eevee aS 149 Estimate the Grossload Times coc cacuivaecentiseltoraeeer 149 Redundancy Object Attributes for Crossload Times 150 Equation for Estimating Crossload Times 0005 151 Program to Minimize Scan Times 225 Poco eee uals Boeke e 152 Use a 1756 L7x Controller with a 1756 RM2 A Redundancy Module wie nd oe cher smtin actin west teg ve ereenn 152 Use Multiple Controlletsi0 02022i4322 vie debi eciedd ahd 152 Minimize the Number of Prograins 4 cecsesesewes con etisies 153 Manage Tags for Efficient Crossloads 00 00sec ee ees 154 Use Concise Programming 45 c1sacdtarmaatuniliwunanmteeeents 157 Program to Maintain Data Integrity vce cig eden aw ee cee 159 Array File Shift Instructions iht06449 944 keg esas 159 Scan dependent LOC cig dhtietee teed esenen aa ennua ors 160 Program to Optimize Task Execution 22 cica ta iat d ene a ree 163 Specify a Larger System Overhead Time Slice 04 164 Change the System Overhead Time Slice 0 0008 166 Use Periodi
309. te these steps to replace alias tags 1 In RSLogix 5000 software open the Controller Tags 2 Press CTRL H to open the Replace Tags dialog box x FindWhet foa o A Find Next Limit to Tetony o YS Find All Replace With CNetforlO ssi Cw Replace Replace AIl Find Where all Tags x i PPM Close Jv Wrap Direction re elp Match Whole Word Only C Up Down Find Withi sc n lt lt Find Within Components Options Base Tag Description iName JType 3 From the Find What pull down menu choose Local 4 From the Replace With pull down menu choose the name of the communication module where the remote I O was placed 5 From the Find Where pull down menu choose All Tags 6 Click Find Within gt gt 7 Select Alias and click Replace All The Search Results tab indicates the changed tags Rockwell Automation Publication 1756 UM535D EN P November 2012 269 AppendixD Convert from a Nonredundant System Remove Other Modules from If modules other than those listed below are in the controller chassis you must the C ontr oll er Ch as sis remove them You can use these modules in ControlLogix enhanced redundancy systems Table 51 Components Available for Use in a Redundant Chassis Pair Module type Cat No Description Available with Enhanced Available with Available with Enhanced Available with System Revision 20 054 Enhanced System
310. ter The time of the update is recorded every time the counter is updated The counter is automatically reset to 0 on a power cycle and may also be reset by clicking the Reset button CH1 Status Fiber Channel 1 status The status shows the operating condition of the respective fiber channels in terms of one of the following values Unknown Operating state is not yet determined Active Channel is operating normally as the ACTIVE channel Redundant Channel is operating normally as the REDUNDANT channel Link Down Channel is disconnected Causes can be the cable is disconnected broken damaged signal is attenuated connector is loose the partner 1756 RM2 module is power down or in a major fault state No SFP No transceiver was detected it has failed it is loosely connected it is not installed SFP Cpt Transceiver is not a Rockwell Automation supported unit SFP Fail Transceiver is in a failed state CH2 Status Fiber Channel 2 status Refer to CH1 Status on page 112 Chassis Platform Configuration Indicates whether configuration is enhanced or standard version 19 05x and above always displays enhanced 1 The Periodic counters can be used to identify a burst of switchovers that may take place due to intermittent channel failures within a few seconds The recorded time may be helpful to correlate the switchover occurrences with any external failures that may have occurred on the
311. th Disqualified Secondary Auto Synchronization State Newer 9 Click OK and close the RMCT Closing the RMCT helps prevent a timeout from occurring when the redundancy module s firmware is upgraded Step 7 Upgrade the Primary Chassis Redundancy Module Firmware Wait 45 seconds before you begin updating the 1756 RM firmware During this time the redundancy module conducts internal operations to prepare for an upgrade 1 Launch ControlFLASH software and click Next 2 Select the redundancy module catalog number and click Next Enter the catalog number of the target device fi 756 RM B 1756 0B 1615 8 1756 0B32 A 1756 0B8 A 1756 0B8E1 A 1756 0C8 A 1756 0H81 A 1756 0N8 A 1756 0W 161 A 1756 0X81 4 1756 RM A al 1756 RM B 1756 RM2 A 1768 L43 1768 L45 Control Le Rockwell Automation Publication 1756 UM535D EN P November 2012 255 Appendix C 256 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System 3 Browse to the module and select it Primary Chassis p J 192 168 1 41 1756 EN2T 1756 EN2T 4 amp Backplane 1756 44 4 _ gt 4 00 1756 L73 LOGIXSS73 Redundancy_update 02 1756 EN2T 1756 EN2T A 03 1756 RM214 1756 RM2 REDUNDANCY MODULE f 192 168 1 42 1756 EN2T 1756 EN2T A amp Backplane 1756 44 4 a OM APES IPO ACTE Nadiman cendabn Secondary Chassis Click OK 5 Select the firmware revision to upgrade to and click Next
312. th the most modules gets the first chance to become primary It becomes primary as long as the other chassis isn t more able to control the system Chassis redundancy state changed to The chassis changed to a different redundancy state PwQS Primary with qualified synchronized secondary partner QSwP Qualified synchronized secondary with primary partner DSwP Disqualified secondary with primary partner DSwNP Disqualified secondary with no partner PwDS Primary with disqualified secondary partner PwNS Primary with no secondary partner e PLU Primary locked for update e SLU Secondary locked for update Crossloading error A module is not able to get some information to its partner Disqualified secondaries 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 Failed modules rule A check to choose a primary chassis if both chassis power up at the same time Suppose that a module in one of the chassis is faulted but its partner module in the other chassis is not faulted In that case the other chassis becomes primary Firmware error The redundancy module has an anomaly Improper mode or mode switch position A lock for update cannot be performed if the primary controller is faulted A lock for up
313. therNet IP communication module are used By default the duplex setting is automatic We recommend that you use this setting whenever possible To avoid communication errors configure both the primary and secondary EtherNet IP communication modules with the same duplex settings Using different duplex settings on partnered EtherNet IP communication modules can result in messaging errors after a switchover Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the EtherNet IP Network Chapter 4 Use An Enhanced A DLR network is a single fault tolerant ring network intended for the interconnection of automation devices This topology is implemented at the Redundancy System Ina device level because the use of EtherNet IP embedded switch technology embeds Device level Ring Topology switches into the end devices themselves No additional switches are required This graphic shows an example DLR network that includes an enhanced redundancy system revision 19 052 or later connected to the network Figure 22 Example DLR Network Products with embedded switch technology have these features in common e Support for the management of network traffic to be sure of timely delivery of critical data e Designed according to the ODVA specification for EtherNet IP networks e Ring recovery time less than 3 m
314. therNet IP communication modules can use IP address swapping to swap IP addresses during a switchover You must use this feature to use Ethernet I O connections For more information on IP address swapping see Chapter 5 Configure the ControlNet Network on page 93 Unicast Functionality Enhanced redundancy systems support unicast produced tags Unicast consumed tags are not supported in enhanced redundancy systems Unicast I O is not supported in a redundancy system Possible Communication Delays on EtherNet IP Networks Brief communication delays can occur for certain connection types if the connection between a component and the redundant chassis pair uses a path exclusively over an EtherNet IP network and a switchover occurs After the switchover is complete communication resumes automatically These connection types can experience the communication delay when the switchover occurs e HMIto redundant chassis pair e FactoryTalk Batch server to redundant chassis pair e FactoryTalk Alarms and Events Service to redundant chassis pair Bridge from an EtherNet IP network to a ControlNet network if you must maintain the connection between the component and a redundant chassis pair in the event of a switchover See HMI Blind Time Reduction on Ethernet During a Switchover on page 21 Rockwell Automation Publication 1756 UM535D EN P November 2012 Design an Enhanced Redundancy System Chapter 2 This example graphic shows
315. these considerations see Chapter 7 Program the Redundant Controller on page 141 IMPORTANT For instructions about how to replace 1756 RM B redundancy modules with 1756 RM2 A redundancy modules without initiating a switchover see Replace 1756 RM A or 1756 RM B Redundancy Modules with 1756 RM2 A Redundancy Modules on page 264 IMPORTANT During a switchover of the fiber channels of the 1756 RM2 A module scan time will encounter a delay of 10 ms however the chassis will remain synched at all times Rockwell Automation Publication 1756 UM535D EN P November 2012 About Enhanced Redundancy Systems Chapter 1 HMI Blind Time Reduction on Ethernet During a Switchover HMI Blind Time is the time during a switchover from primary to secondary when tag data from the controller is unavailable for reading or writing HMI Blind Time is associated with visualizing process operations from an HMI however it is applicable to any software that uses tag data such as data loggers alarming systems or historians Reducing HMI Blind Time is important to avoid shutdowns Brief communication interruption occurs if the connection between RSLinx Enterprise software and the redundant chassis pair uses a path exclusively over an EtherNet IP network and a switchover occurs After the switchover is complete communication resumes automatically The time between the communication updating active data interruption and the restoration resumes update
316. tic 7 Click OK Rockwell Automation Publication 1756 UM535D EN P November 2012 213 Chapter9 Troubleshoot a Redundant System Export Diagnostics IMPORTANT Only Export Diagnostics when requested to do so by Rockwell Automation Technical Support You can also click Export Diagnostics in the event of a module fault in the 1756 redundancy module Click Export Diagnostics to collect and save diagnostic data from the redundancy module and its partner if an unrecoverable firmware fault occurs A nonrecoverable fault is indicated by a red OK light on the front of the redundancy module and a fault message scrolling across the marquee display When you click Export Diagnostics information is recorded that can be used by Rockwell Automation engineering to determine the cause of the fault Because diagnostic information for the redundancy module and its redundancy partner are recorded a communication path to the partner RM is also part of the process of obtaining the diagnostics Follow these steps 1 Click Clear Fault if it is enabled as it may first be necessary to clear any faults before using Export Diagnostics 2 Click Export Diagnostics Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History r Auto Update Chassis amp Event 880557 880556 880555 880554 880553 880552 880551 RANSKAN Chassis B Event 1117269 1117268 1117267 1
317. tion Synchronization Status Event Log System Update System Even r Redundancy Commands Synchronize Secondary Disquality Secondary Initiate Switchower r Recent Synchronization Attempts Order Result Cause N Success n N 1 Success N 2 Synchronization not attempted N 3 Synchronization not attempted Click Synchronize Secondary then click Yes After the redundant chassis pair synchronizes click Initiate Switchover from the Synchronization tab in the RMCT then click Yes Module Info Configuration Synchronization Synchronization Status Event Log System Update System Event History m Redundancy Commands Synchronize Secondary Disqualify Secondary Initiate Switchover Become Primat m Recent Synchronization Attempts Order Result N Success N 1 Success N 2 Synchronization not attempted N 3 Synchronization not attempted In RSLinx Classic software select Module Configuration on the new primary Ethernet communication module Click the Port Configuration tab and change the Gateway address from 0 0 0 0 to 192 168 1 1 Click Apply then click OK Disconnect the Ethernet cable or cables from the secondary Ethernet module In ControlIFLASH software bridge across the backplane or use the Ethernet module s USB port and update the new secondary Ethernet module to firmware revision 5 008 When the update is complete the Up
318. tion see the section titled Redundant Chassis on page 28 Once you have made the appropriate changes to your system configuration and program and have added the identical chassis upgrade your system firmware For information about upgrading the redundant system firmware see Step 4 Update Redundant Chassis Firmware on page 67 After you upgrade the firmware use RSLogix 5000 software to access the controller properties and update the controller revision to match the redundancy firmware revision you are using To Type 1756 L73 ControlLogix5573 Controller v Revision 20 v Once you have updated the controller firmware revision and saved the changes download the updated program to the controller Rockwell Automation Publication 1756 UM535D EN P November 2012 271 AppendixD Convert from a Nonredundant System Notes 272 Rockwell Automation Publication 1756 UM535D EN P November 2012 Appendix E Redundancy Object Attributes Use this table of redundancy object attributes as a reference when programming to obtain the status of your redundancy system For this information Get this attribute Data GSV SSV Description Type Redundancy status of the entire ChassisRedundancyState INT GSV If Then chassis 16 2 Primary with synchronized secondary 16 3 Primary with disqualified secondary 16 4 Primary with no secondary 16 10 Primary locked for update Redundancy state of the partner Partn
319. tion Time Status Result N 7 23 2009 17 11 38 442 Locked System locked at 7 23 2009 17 12 10 123 ae Lock complete P Chassis Ac Primarg_Locked For Update Abort System Lock The Abort System Lock command can be used to stop the system lock It is available as soon as a lock for update is initiated Clicking Abort System Lock returns the redundant chassis status to Primary with Disqualified Secondary Clicking Abort System Lock also results in the system update stopping and the program in the secondary controller being cleared If you click Abort System Lock you need to download the program to the secondary controller before re attempting a Lock for Update 132 Rockwell Automation Publication 1756 UM535D EN P November 2012 Configure the Redundancy Modules Chapter 6 Initiate Locked Switchover The Initiate Locked Switchover command is available only when the chassis redundancy state is Primary with Locked Secondary That is the Initiate Locked Switchover is available only after the lock for update is complete Clicking Initiate Locked Switchover results in your secondary chassis assuming control and becoming the new primary The old primary is now the new secondary chassis and you can update the firmware of the modules in the new secondary chassis Figure 32 Illustration of Switchover Chassis A Chassis B mam 1756 EN2T 1756 EN2T Primary Secondary Chassis B Chass
320. ualification 19 switchover 19 synchronization 19 optical ports 59 P Partial Import Online 182 periodic task 167 execution 147 recommended 145 power supplies 55 power supply 25 34 52 install 54 55 redundant power supplies 34 primary 246 primary chassis 19 designate 71 designation 71 74 installation 54 62 produce consume connections over ControlNet 93 over EtherNet IP 35 84 produced tags unicast 85 program crossload default 145 scan time 149 enable user control 115 finalize test edits 186 logic after switchover 170 maintain data integrity 159 162 manage tags 154 messages for redundancy commands 171 175 monitor system status 190 obtain system status 168 online edits 182 188 optimize task execution 163 168 Partial Import Online 182 periodic task 167 reserve memory 187 scan time minimize 152 158 synchronization default 145 system overhead time slice 164 tags 154 task type 145 test edits 183 use concise 157 project save 102 PsDS qualification status indicators 211 PwNS qualifcation status indicators 211 PwQS qualification status indicators 211 Q QSwP qualification status indicators 211 qualification after designation 73 check in RMCT 194 check status 192 description of 19 status via RMCT 74 troubleshoot nonredundant controller 225 qualification status indicators 211 DSwNP 211 DSwP 211 PwDS 211 PwNS 211 PwQS 211 QSwP 211 qualify redundant module 74 quick start enhanced redun
321. ule If the error persists replace the module CONFIG Erase Error Error in erasing NVS device while updating configuration log image Cycle power to the redundancy module If the error persists replace the module CONFIG Program Error Error in writing in NVS device while updating configuration log image Cycle power to the redundancy module If the error persists replace the module EEPROM Write Error Error in writing in EEPROM device while updating configuration log image Cycle power to the redundancy module If the error persists replace the module Application Update Required The module is running boot firmware Download the application firmware obtained from the respective redundancy bundle ICPT Atest line on the backplane is asserted Check if the error message goes away after removing each module one at a time If error persists cycle power to the chassis or replace the chassis Cpt All modules in the chassis do not belong to the same standard or enhanced redundancy platform Untrusted Certificate Error The 1756 RM2 A and 1756 RM2xXT modules use signed firmware This error appears when either the contents of the downloaded certificate or its signature for the downloaded firmware is invalid Rockwell Automation Publication 1756 UM535D EN P November 2012 OK Status Indicators Status Indicators Appendix A The OK status indicator reveals the current redundancy module state Table 41 OK Status Ind
322. ules When Rotary Switches Are Set between 2 254 on page 244 IMPORTANT You can only upgrade from firmware revision 19 052 or later to firmware revision 20 054 These steps apply when upgrading from firmware revision19 052 or later to firmware revision 20 054 Complete these steps to upgrade your redundancy system from one enhanced redundancy system revision to another enhanced redundancy revision while your process continues to run Step 1 Before You Begin Step 2 Upgrade the Workstation Software Step 3 Download and Install the Redundancy Firmware Bundle Step 4 Upgrade the Redundancy Module Configuration Tool 1 2 3 4 5 Step 5 Add the EDS Files 6 Step 6 Prepare the Redundant Chassis for the Firmware Upgrade 7 8 Step 7 Upgrade the Primary Chassis Redundancy Module Firmware Step 8 Upgrade the Secondary Redundancy Module Firmware and All Other Modules Firmware in the Secondary Chassis Step 9 Prepare the RSLogix 5000 Project for the Upgrade 10 Step 10 Lock the System and Initiate a Switchover to Upgrade 11 Step 11 Upgrade the New Secondary Chassis Firmware X 12 Step 12 Synchronize the Redundant Chassis 250 Rockwell Automation Publication 1756 UM535D EN P November 2012 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C Step 1 Before You Begin Consider these points before you begin upgrading your enhanced re
323. ules are used with 1756 L7x controllers IMPORTANT _ Thescan time is slightly extended when you downgrade a Series B redundancy module to a Series A module in conjunction with a 1756 L7x controller in the redundant chassis pair In this case raise the task watchdog limits by a factor of 2x before downgrading Thereafter you can re tune the limits based on the updated scan time numbers If your application uses 1756 L6x controllers in the redundant chassis pair using a combination of Series A and Series B redundancy modules results in the same performance as if you use only a Series A redundancy module in the redundancy chassis pair regardless of the primary or secondary redundancy state A fiber optic cable connects the redundancy modules in the redundant chassis pair These are catalog numbers of fiber optic cable you can order from Rockwell Automation e 1756 RMC1 1 m 3 28 ft e 1756 RMCG3 3 m 9 84 ft e 1756 RMC10 10 m 32 81 ft If necessary you can make your own fiber optic cable that is up to 4 km 13 123 36 ft for the 1756 RM B module or 10 km 32 808 40 ft for the 1756 RM2 module 278 Rockwell Automation Publication 1756 UM535D EN P November 2012 Enhanced Redundancy System Checklists Appendix F ControlLogix Controller Checklist v Requirement Identical ControlLogix controllers are placed in the same slot of both chassis of the redundant pair Partnered controllers are identical in redundancy firmware revis
324. ultiple controllers in your redundant system If you use multiple controllers you can strategically program between the controllers so the program execution and scan times are faster For more information about controllers that can be paired in redundant chassis see Components of an Enhanced Redundancy System on page 24 Rockwell Automation Publication 1756 UM535D EN P November 2012 Program the Redundant Controller Chapter 7 Minimize the Number of Programs When programming a redundant controller use the fewest programs possible Using the fewest programs possible is especially important if you plan to crossload data and synchronize the controllers after the execution of each program If you need to crossload data at the end of each program make these programming considerations to minimize the crossload impact on the program scan time e Use only one or a few programs e Divide each program into the number of routines that is appropriate for your application A routine does not cause a crossload or increase the scan time e Use the main routine of each program to call the other routines of the program e Ifyou want to use more than one task for different scan periods use only one program in each task Figure 39 Use of Multiple Routines preferred Figure 39 Use of Multiple Programs not preferred 3 Tis H S Tasks 38 MainTask aari MainTask MainProgram MainProgram
325. undant system Reestablishment and monitoring of 1 0 connections such as Removal and Insertion Under Power conditions This does not include normal 1 0 updates that occur during the execution of logic Bridging of communication from the serial port of the controller to other ControlLogix devices via the ControlLogix backplane To increase service communication to allow for synchronization and the updating of HMI consider using the techniques described in this table Table 27 Methods to Increase Service Communication Periods Then see If your RSLogix 5000 project contains On Page Only a continuous task with no other tasks This is the default task configuration Specify a Larger System Overhead Time Slice More than one task for example at least 2 periodic tasks Use Periodic Tasks 167 Rockwell Automation Publication 1756 UM535D EN P November 2012 163 Chapter 7 164 Program the Redundant Controller Specify a Larger System Overhead Time Slice The system overhead time slice specifies the percentage of time the controller devotes to servicing communication excluding the time for periodic tasks The controller interrupts the continuous task to service communication and then resumes the continuous task This table shows the ratio between executing the continuous task and servicing communication at various overhead time slices Consider the following e When the system overhead tim
326. us task execution Communication is serviced for up to 1 ms before the continuous task is restarted Figure 49 System Overhead Time Slice Set to 33 1ms 1ms 1ms 1ms 1ms 1ms 1ms 1ms ov min eeeeesed 2ms 2ms 2ms 2ms 2ms 2ms 2ms 2ms 2ms Continuous Task E E HE HE E HEHEHE H Rockwell Automation Publication 1756 UM535D EN P November 2012 165 Chapter 7 166 Program the Redundant Controller Change the System Overhead Time Slice To change the System Overhead Time Slice access the Controller Properties dialog box and click the Advanced tab You can enter your System Overhead Time Slice value General Serial Port System Protocol User Protocol Major Faults Date Time Advanced SFC Execution File Redundancy Nonvolatile h Power Up Handler knone gt v p gt _ System Overhead 20 E Time Slice z m During unused System Overhead Time Slice Run Continuous Task C Reserve for System Tasks eg Communications Security Nin Protection v Options for During the Unused System Overhead Time Slice Enable the Run Continuous Task option default setting if you want the controller to revert to running the continuous task as soon as the communication servicing task has no pending activity This has the effect of only using the allocated communication servicing time if there is a need for it When the Run Continuous Task option enabled the controller immediately returns to the continuous task Use
327. v Edits Enabled From the Network menu choose Properties In the Network Parameters tab update the parameters specific to your system Network Update Time ms Max Scheduled Address Max Unscheduled Address Media Redundancy Network Name Click OK Network Parameters Media Configuration General Current 5 00 A Only defaut From the File menu choose Save lA Only gt _defaut From the Network menu choose Single Pass Browse Click Optimize and re write schedule for all connections and click OK Save Type Optimize and re write schedule for all connections Werge changes inte existing schedule Click OK Rockwell Automation Publication 1756 UM535D EN P November 2012 You have completed updating your scheduled ControlNet network Check the Network Keeper States Active and valid keeper device Configure the ControlNet Network Chapter 5 After you schedule your ControlNet network check the states of keeper capable nodes Checking the status of keeper capable nodes is important because if a major network disruption occurs the keepers provide network configuration parameters required to recover For more information about keepers and their function in a ControlNet network see the ControlNet Modules in Logix5000 Control Systems User Manual publication CNET UMO001 To check the status of keepers on the ControlNet network complete these steps 1 In RS
328. vent Complete these steps to export event log data for a single event TIP Ifthe redundancy modules are not available in RSLinx Classic software after a fault you must apply the recovery method indicated by the module before attempting to export the Event Log data 1 Launch RSLinx Classic communication software and browse to the redundancy modules 2 Right click the primary redundancy module and choose Module Configuration 3 On the Event Log tab click Export All Export All 4 Click OK 5 Select the redundancy module in the partner redundant chassis 6 Complete these steps on the Export Event Log dialog box a Specify a file name and location or use the default name and location b Check CSV Comma Separated Value TIP If you are sending the exported Event Log files to Rockwell Automation Technical Support you must use the CSV file type c Check Export Diagnostic Data d Check Include Extended Information TIP If you are sending the exported Event Log files to Rockwell Automation Technical Support include the diagnostic data and extended information If you include this data Rockwell Automation Technical Support can analyze module and system failures more effectively Rockwell Automation Publication 1756 UM535D EN P November 2012 127 Chapter6 Configure the Redundancy Modules 7 Click Export Export Event Log x C 4642218_chassis_B 11162010_1640 csv Export Diagnostic aE
329. version nonredundant to redundant 73 convert nonredundant to redundant 265 271 CPU usage Ethernet IP 77 crossload 57 1756 RM2 A 151 ControlNet keepers 102 default 145 estimate 149 redundancy object attributes 150 redundant system 19 scan time 149 D Data Highway Plus 43 date and time 115 designate primary chassis 71 designation chassis 71 conduct 19 qualification after 73 device level ring network 35 87 beacon interval 88 beacon timeout 88 DeviceNet 43 DLR ring node 88 supervisor node 87 DSwNP qualification status indicators 211 DSwP qualification status indicators 211 dual fiber ports 1756 RM2 A 138 duplex setting 86 edit system event 137 EDS files 54 electrostatic discharge 58 elements of DLR network 87 enable user program control 115 enhanced redundancy system chassis 28 communication modules 32 components 17 24 controllers 29 features 16 Operations 19 power supply 34 quick start 51 redundancy modules 31 redundant power supplies 34 restrictions 22 using ControlNet 38 using EtherNet IP 35 37 environmental considerations 51 Ethernet 52 HMI blind time 21 EtherNet IP 1715 Redundant I 0 systems 16 configure module 85 delay 36 device level ring network 35 duplex setting 86 features available in system revision 19 052 only 35 IP address swapping 36 77 79 modules 24 overview 42 produce consume connections 35 84 remote 1 0 16 18 requested packet interval 77 requireme
330. w primary controller after a switchover e Ifedits exist in the primary controller due to a PIO they are treated the same as normal test edits with respect to the Retain Test Edits at Switchover selection and Redundancy System Update e The primary controller rejects any attempt to qualify ifa PIO is in progress e Ifyou attempt to initiate a PIO on a primary controller in the process of qualifying the system that PIO is rejected Rockwell Automation Publication 1756 UM535D EN P November 2012 Program the Redundant Controller Chapter 7 e APIO toa primary controller may fail if a switchover occurs while the PIO is still in process When the anomaly occurs and the PIO fails you may see any of these errors Failed to import file c xxx L5x Object already exists Failed to import file c xxx L5x Already in request mode state CIP error Problem with a semaphore Internal Object Identifier IOI destination unknown After switchover is complete re attempt the PIO and it completes successfully There are additional considerations necessary to performing online edits e Plan for Test Edits e Reserve Memory for Tags and Logic e Finalize Edits with Caution Plan for Test Edits Before you begin making edits to your redundant program while your system is running verify that the Retain Test Edits on Switchover setting meets your application requirements IMPORTANT We recommend that you leave the
331. wkts tee sakeeeeree de woniollivaninted dete 56 Install the Redundancy Module 3 3 0 4 aeieeh eerie 57 Environment and Enclosure 0 cccccccececcvcueveveee 58 Prevent Electrostatic Discharge 22 cvs dovseuveadssen aeeee ieee 58 Removal and Insertion Under Power RIUP 005 58 European Hazardous Location Approval 00 2000 58 Safety related Programmable Electronic Systems 59 Optical Portsie remie e a a sual a sek 59 Small Form factor Pluggable 2 c5xiwpesendsgestusy eas cos teiee 59 North American Hazardous Location Approval 60 Laser Radiation Porte i icky eke tet uh seen dn eee ll fuk 60 Install the Second Hassisisa e ete ei ie es dae 63 Step 3 Connect the Redundancy Modules via a Fiber optic Cable 63 Connect the Fiber optic Communication Cable to Redundant Channels sice nr r a a sad Cocke Gteae wee nde EEG 65 Connect the Fiber optic Communication Cable to Single Channels scahicnitawerseenee EEEE EE EAE EADE 66 Piberoptic Gable nce oF daire teen ease a coe 67 Step 4 Update Redundant Chassis Firmware 0e eee sees 67 Upgrade the Firmware in the First Chassis 00005 68 Upgrade the Firmware in the Second Chassis 008 71 Step 5 Designate the Primary and Secondary Chassis 71 After Designations sssri erii tini cee eaan E 73 Conversion from a Nonredundant to a Redundant System 73 Qualification Status via
332. y no longer available after the conversion from a standard redundancy system to an enhanced redundancy system e Simple Network Time Protocol SNTP Client e Web pages You must account for this lost functionality in your RSLogix 5000 software project Updating Communication Settings Make sure you set all network settings for example node addresses or IP addresses required to your application in the new communication modules For more information on specific communication module series and firmware revision levels required in an enhanced redundancy system see http www rockwellautomation com support americas index_en hunl 242 Rockwell Automation Publication 1756 UM535D EN P November 2012 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C Steps After System Components Upgrade Complete these remaining steps after upgrading the necessary components to an enhanced redundancy system 1 Apply power to the primary chassis 2 Update and load the controller program IMPORTANT Ifyou have an existing RSLogix 5000 program for the controller update the program to reflect the new modules and firmware revisions Updates required may include changes to tags message paths and controller properties depending on your application 3 Ifused reschedule the ControlNet network For more information about rescheduling the ControlNet network see Update an Existing Scheduled Network
333. ystem Protocol User Protocol l Major Faults Minor Faults Date Time Advanced SFCExecution File Redundancy Nonvolatile Memory Memory This controller is not enabled for use in a Redundancy Enabled redundant system Redundancy status If Redundancy Enabled is not selected then take these actions e Doone of the following Remove the controllers that are not Redundancy Enabled Enable the controller for redundancy and make other program changes to accommodate redundancy e After removing or correcting the Redundancy Enabled setting attempt to synchronize your redundant system again Controller Events Occasionally controller related events may be logged in the RMCT Event Log In some cases the anomalies are strictly status updates and are not indicative of an anomaly that requires troubleshooting In other cases the event description may indicate Program Fault Cleared or a similar description of a resolved anomaly If these types of events are not followed by state changes or switchovers then they are not indicative of an anomaly that requires additional troubleshooting If an event logged for a controller in the redundant system is followed by a state change or switchover use RSLogix 5000 software to go online with the controller and determine the cause of the fault For more information about using RSLogix 5000 software to troubleshoot a fault see the section titled Use RSLogix 5000 Software to View
334. zed Primary Full Rockwell Automation Publication 1756 UM535D EN P November 2012 119 Chapter6 Configure the Redundancy Modules Event Log Tab The Event Log tab provides a history of events that have occurred on the redundant chassis These system events are indicated in the event logs e Qualification stages entered and completed e Module insertion removal e Firmware errors e Communication events and errors e Configuration changes e Other system events that affect qualification and synchronization IMPORTANT The events logged in this tab are not always indicative of an error Many of the events logged are informational only To determine if additional action or troubleshooting is required in response to an event see the Event Classifications table on page 121 The Event Log tab can be customized to view the log specific to only one chassis or the event logs of both redundant chassis You can alter your view of the event logs by changing the Auto Update and Partner Log parameters Table 20 Settings for Event Log Views Use this setting Auto Update Keep the log from updating while you re viewing it Partner Log View only the event log for the module you are accessing Figure 29 Settings for Event Log Views Check On to keep the log updating automatically Check Close to view only the log of one redundancy module Mo le Info Configuration Sync nization Synchronization Status Event Log System Update Syste

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