Rockwell Automation 1756-RMxx User Manual
User Manual
ControlLogix Enhanced Redundancy System
Catalog Numbers 1756-RM, 1756-RMXT, 1756-RM2, 1756-RM2XT
Important User Information
IMPORTANT
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1
your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/
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, 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.
available from
) describes some
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.
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, R SNetWorx, VersaView, RSView32, Logix5000, ControlLogix-XT,
Integrated Architecture, Stratix 8000, PowerFlex, POINT I/O are trademarks of Rockwell Automation, Inc.
Trademarks not belonging 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 Information
This table contains the changes made to this publication revision.
Table 1 - New and Updated Information
Top ic Pa ge
This publication includes the addition of the 1756-RM2/A and 1756-RM2XT 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-RM2XT 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
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
changes for the 1756-RM2/A and 1756-RM2XT modules.
The revision has been updated wherever the 1756-L7x controller appears in this manual
to 19.053.
Added new firmware bundles 20.054_kit1, 19.053_kit1, and 19.081_kit1. 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
other 1756-RM2/A or 1756-RM2XT modules. You cannot mix 1756-RM2/A and 1756RM2XT 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
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
20
24
27
57
64
Rockwell Automation Publication 1756-UM535D-EN-P - November 2012 3
Summary of Changes
Table 1 - New and Updated Information
Top ic Pa ge
SFP error message. 230
Added missing Module Status Display descriptions for the 1756-RM/A and 1756-RM/B
modules.
Replace 1756-RM/B redundancy modules with 1756-RM2/A redundancy modules
without initiating a switchover.
231
264
4 Rockwell Automation Publication 1756-UM535D-EN-P - November 2012
Table of Contents
Preface
About Enhanced Redundancy
Systems
Design an Enhanced Redundancy
System
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 1
Features of the ControlLogix Enhanced Redundancy System . . . . . . . . 16
Enhanced Redundancy System Components . . . . . . . . . . . . . . . . . . . . . . . 17
I/O Modules in Enhanced Redundancy Systems . . . . . . . . . . . . . . . . 18
Enhanced Redundancy System Operations . . . . . . . . . . . . . . . . . . . . . . . . . 19
System Qualification and Synchronization . . . . . . . . . . . . . . . . . . . . . 19
Switchovers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Chapter 2
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
EtherNet/IP Networks with Redundant Systems . . . . . . . . . . . . . . . . . . . 35
EtherNet/IP Network Features in an Enhanced
Redundancy System, Revision 19.052 or Later . . . . . . . . . . . . . . . . . . 35
IP Address Swapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Unicast Functionality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Possible Communication Delays on EtherNet/IP Networks . . . . . 36
ControlNet Networks with Redundant Systems . . . . . . . . . . . . . . . . . . . . 38
ControlNet Network Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Redundant ControlNet Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Other Communication Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
I/O Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1715 Redundant I/O Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Using HMI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
HMI Connected via an EtherNet/IP Network. . . . . . . . . . . . . . . . . . 46
HMI Connected via a ControlNet Network. . . . . . . . . . . . . . . . . . . . 47
Firmware Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Software Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Required Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Optional Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Install the Enhanced Redundancy
System
Chapter 3
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Enhanced Redundancy System Quick Start . . . . . . . . . . . . . . . . . . . . . 51
Install an Enhanced Redundancy System . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Step 1: Install the Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Rockwell Automation Publication 1756-UM535D-EN-P - November 2012 5
Table of Contents
Install the Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Add the EDS Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Step 2: Install the Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Install the First Chassis and its Components . . . . . . . . . . . . . . . . . . . . 54
Install the Chassis and Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Install the Communication Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Install a Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Install the Redundancy Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Environment and Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Prevent Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Removal and Insertion Under Power (RIUP) . . . . . . . . . . . . . . . . . . . 58
European Hazardous Location Approval . . . . . . . . . . . . . . . . . . . . . 58
Safety-related Programmable Electronic Systems . . . . . . . . . . . . . . . . 59
Optical Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Small Form-factor Pluggable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
North American Hazardous Location Approval. . . . . . . . . . . . . . . . . 60
Laser Radiation Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Install the Second Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Step 3: Connect the Redundancy Modules via a Fiber-optic Cable . . . . 63
Connect the Fiber-optic Communication Cable to Redundant
Channels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Connect the Fiber-optic Communication Cable to
Single Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Fiber-optic Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Step 4: Update Redundant Chassis Firmware . . . . . . . . . . . . . . . . . . . . . . . 67
Upgrade the Firmware in the First Chassis . . . . . . . . . . . . . . . . . . . . . . 68
Upgrade the Firmware in the Second Chassis . . . . . . . . . . . . . . . . . . . 71
Step 5: Designate the Primary and Secondary Chassis. . . . . . . . . . . . . . . . 71
After Designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Conversion from a Nonredundant to a Redundant System . . . . . . . 73
Qualification Status via the RMCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Reset the Redundancy Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Remove or Replace the Redundancy Module. . . . . . . . . . . . . . . . . . . . 75
Chapter 4
Configure the EtherNet/IP Network
6 Rockwell Automation Publication 1756-UM535D-EN-P - November 2012
Requested Packet Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
CPU Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Use IP Address Swapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Static versus Dynamic IP Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Reset the IP Address for an EtherNet/IP Communication
Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Use CIP Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Use Produce/Consume Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Configure EtherNet/IP Communication Modules in a
Redundant System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Table of Contents
Options for Setting the IP Addresses of EtherNet/IP
Communication Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Half/Full Duplex Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Use An Enhanced Redundancy System in a Device-level
Ring Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Chapter 5
Configure the ControlNet Network
Configure the Redundancy Modules
Produce/Consume Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Network Update Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
NUTs with Multiple ControlNet Networks. . . . . . . . . . . . . . . . . . . . 95
Use a Scheduled or Unscheduled Network . . . . . . . . . . . . . . . . . . . . . . . . . 97
Use a Scheduled Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Use an Unscheduled Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Add Remote ControlNet Modules While Online . . . . . . . . . . . . . . . 98
Schedule a New Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Update an Existing Scheduled Network. . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Check the Network Keeper States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Save the Project for Each Primary Controller . . . . . . . . . . . . . . . . . . 102
Automatic Keeper Crossloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Chapter 6
About the Redundancy Module Configuration Tool (RMCT) . . . . . 105
Determine if Further Configuration is Required . . . . . . . . . . . . . . . . . . . 106
Use the RMCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Identify the RMCT Version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Update the RMCT Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Module Info Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Configuration Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Auto-Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Chassis ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Enable User Program Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Redundancy Module Date and Time. . . . . . . . . . . . . . . . . . . . . . . . . . 115
Synchronization Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Commands in the Synchronization Tab . . . . . . . . . . . . . . . . . . . . . . . 117
Recent Synchronization Attempts Log . . . . . . . . . . . . . . . . . . . . . . . . 118
Synchronization Status Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Event Log Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Event Classifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Access Extended Information About an Event . . . . . . . . . . . . . . . . . 123
Interpret an Event’s Extended Information . . . . . . . . . . . . . . . . . . . . 124
Export Event Log Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Clear a Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
System Update Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
System Update Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
System Update Lock Attempts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Locked Switchover Attempts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Rockwell Automation Publication 1756-UM535D-EN-P - November 2012 7
Table of Contents
Program the Redundant Controller
System Event History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Edit a User Comment for a System Event . . . . . . . . . . . . . . . . . . . . . . 137
Save System Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Using Dual Fiber Ports with the 1756-RM2/A Redundancy Module 138
Fiber Channel Switchover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Monitoring and Repair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Chapter 7
Configure the Redundant Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Crossloads, Synchronization, and Switchovers . . . . . . . . . . . . . . . . . . . . . 144
Changing Crossload and Synchronization Settings . . . . . . . . . . . . . 144
Default Crossload and Synchronization Settings . . . . . . . . . . . . . . . 145
Recommended Task Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Continuous Task After Switchover . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Multiple Periodic Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Crossloads and Scan Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Estimate the Crossload Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Redundancy Object Attributes for Crossload Times . . . . . . . . . . . . 150
Equation for Estimating Crossload Times . . . . . . . . . . . . . . . . . . . . . 151
Program to Minimize Scan Times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Use a 1756-L7x Controller with a 1756-RM2/A
Redundancy Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Use Multiple Controllers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Minimize the Number of Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Manage Tags for Efficient Crossloads. . . . . . . . . . . . . . . . . . . . . . . . . . 154
Use Concise Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Program to Maintain Data Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Array (File)/Shift Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Scan-dependent Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Program to Optimize Task Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Specify a Larger System Overhead Time Slice . . . . . . . . . . . . . . . . . . 164
Change the System Overhead Time Slice . . . . . . . . . . . . . . . . . . . . . . 166
Use Periodic Tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Program to Obtain System Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Program Logic to Run After a Switchover . . . . . . . . . . . . . . . . . . . . . . . . . 170
Use Messages for Redundancy Commands . . . . . . . . . . . . . . . . . . . . . . . . 171
Verify User Program Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Use an Unconnected Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Configure the MSG Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Set the Task Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Minimum Value for the Watchdog Time . . . . . . . . . . . . . . . . . . . . . . 177
Download the Project. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Store a Redundancy Project to Nonvolatile Memory . . . . . . . . . . . . . . . 178
Store a Project While the Controller is in Program or
Remote Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Store a Project While a System is Running . . . . . . . . . . . . . . . . . . . . . 181
8 Rockwell Automation Publication 1756-UM535D-EN-P - November 2012
Monitor and Maintain an Enhanced
Redundancy System
Table of Contents
Load a Project. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Online Edits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Support for Partial Import Online . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Plan for Test Edits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Finalize Edits with Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Reserve Memory for Tags and Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Chapter 8
Tasks to Monitor the System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Controller Logging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Controller Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Controller Logging in Enhanced Redundancy Systems . . . . . . . . . 190
Use Programming to Monitor System Status . . . . . . . . . . . . . . . . . . . . . . 190
Verify Date and Time Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Verify System Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Check Qualification Status via Module Status Displays . . . . . . . . . 192
Check Qualification Status via the RMCT . . . . . . . . . . . . . . . . . . . . 194
Conduct a Test Switchover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Synchronization After a Switchover. . . . . . . . . . . . . . . . . . . . . . . . . . . 196
Check the ControlNet Module Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
CPU Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Connections Used. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Monitor the ControlNet Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Troubleshoot a Redundant System
Chapter 9
General Troubleshooting Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Check the Module Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Use RSLogix 5000 Software to View Errors . . . . . . . . . . . . . . . . . . . . . . . 201
Redundant Controller Major Fault Codes. . . . . . . . . . . . . . . . . . . . . 203
Use the RMCT for Synchronization Attempts and Status . . . . . . . . . . 204
Recent Synchronization Attempts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Module-level Synchronization Status. . . . . . . . . . . . . . . . . . . . . . . . . . 205
Use the RMCT Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Interpret Event Log Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Export All Event Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Export Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Contact Rockwell Automation Technical Support . . . . . . . . . . . . . 216
Keeper Status Causing Synchronize Failure. . . . . . . . . . . . . . . . . . . . . . . . 216
Check the Module Status Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Check Keeper Status in RSNetWorx for ControlNet Software . . 217
Valid Keeper Status and Signatures . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
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
Rockwell Automation Publication 1756-UM535D-EN-P - November 2012 9
Table of Contents
Appendix A
Status Indicators
Event Log Descriptions
Upgrade from a Standard
Redundancy System or to Another
Enhanced Redundancy System
Redundancy Module Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
1756-RM2/A and 1756-RM2XT Status Indicators. . . . . . . . . . . . . 227
1756-RM/A and 1756-RM/B Status Indicators . . . . . . . . . . . . . . . . 230
Redundancy Module Fault Codes and Display Messages . . . . . . . . 233
Recovery Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Appendix B
Event Log Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
Appendix C
Upgrade from a Standard Redundancy System . . . . . . . . . . . . . . . . . . . . . 239
Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
Upgrade System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Upgrade the System Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Upgrade the Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
Replace Communication Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
Steps After System Components Upgrade . . . . . . . . . . . . . . . . . . . . . 243
Upgrade Ethernet Modules When Rotary Switches Are Set
between 2…254. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
Upgrade by Using Redundancy System Update . . . . . . . . . . . . . . . . . . . . 250
Replace 1756-RM/A or 1756-RM/B Redundancy Modules with
1756-RM2/A Redundancy Modules . . . . . . . . . . . . . . . . . . . . . . . . . . 264
Convert from a Nonredundant
System
Redundancy Object Attributes
Enhanced Redundancy System
Checklists
Appendix D
Update the Configuration in RSLogix 5000 Software . . . . . . . . . . . . . . 266
Replace Local I/O Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Replace Aliases to Local I/O 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
Appendix E
Redundancy Object Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Appendix F
Chassis Configuration Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Remote I/O Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Redundancy Module Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
ControlLogix Controller Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
ControlNet Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
EtherNet/IP Module Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Project and Programming Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
10 Rockwell Automation Publication 1756-UM535D-EN-P - November 2012
Appendix G
Table of Contents
Enhanced Redundancy Revision
History
Index
Changes to This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Rockwell Automation Publication 1756-UM535D-EN-P - November 2012 11
Table of Contents
Notes:
12 Rockwell Automation Publication 1756-UM535D-EN-P - November 2012
Preface
IMPORTANT
This publication provides this information specific to enhanced redundancy
systems:
• Design and planning considerations
• Installation procedures
• Configuration procedures
• Maintenance and troubleshooting methods
This publication is designed for use by anyone responsible for planning and
implementing a ControlLogix® enhanced redundancy system:
• Application engineers
• Control engineers
• Instrumentation technicians
The contents of this publication are for those who already have an understanding
of Logix5000™ control systems, programming techniques, and communication
networks.
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 I/O Specifications, publication 1715-TD001
1715 Redundant I/O System User Manual, publication 1715-UM001
ControlLogix Controllers User Manual, publication 1756-UM001
Logix5000 Controllers General Instructions Reference Manual, publication 1756-RM003
Logix5000 Controllers Quick Start, publication 1756-QS001. Provides detailed information about how to use ControlLogix controllers.
ControlFLASH™ Firmware Upgrade Kit Quick Start, publication 1756-QS105
Industrial Automation Wiring and Grounding Guidelines, publication
1770-4.1
Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and other certification details.
Contains specifications on a Redundant I/O system.
Contains information on how to install, configure, program, operate and troubleshoot a
Redundant I/O system.
Contains information on how to install, configure, program, and operate a ControlLogix
system.
Contains information on RSLogix™ 5000 programming instructions.
Contains information on how to upgrade module firmware.
Provides general guidelines for installing a Rockwell Automation industrial system.
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 Description
1756 Communication Modules Specifications Technical Data, publication 1756-TD003
ControlNet Modules in Logix5000 Control Systems User Manual, publication CNET-UM001
EtherNet/IP Modules in Logix5000 Control Systems, publication
ENET-UM001
Ethernet Design Considerations for Control System Networks, publication ENET-SO001 Provides fundamental best-practice guidelines for designing the Ethernet
EtherNet/IP Embedded Switch Technology Application Guide, publication ENET-AP005
EtherNet/IP Socket Interface Application Technique, publication ENET-AT002
Describes Ethernet communication module specifications.
Describes ControlNet modules and how to use ControlNet modules with a Logix5000
controller.
Describes how to use EtherNet/IP communication modules with your Logix5000
controller and communicate with various devices on the Ethernet network.
infrastructure for your Supervisory Controls and Data Acquisition (SCADA) and MES
(Manufacturing Execution Systems) systems with Rockwell Automation software and
hardware products.
Describes how to configure and implement a device-level ring topology.
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 1
About Enhanced Redundancy Systems
Top ic Pa ge
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
Chapter 1 About Enhanced Redundancy Systems
Features of the ControlLogix Enhanced Redundancy System
The software and hardware components required to configure and use a
ControlLogix enhanced redundancy system provide these features:
• Redundancy module speeds of up to 1000 Mbps when using a 1756RM2/A module with another 1756-RM2/A module. Redundancy
module speeds up to 100 Mbps when using a 1756-RM/A with another
1756-RM/A module, and a 1756-RM/B module with another 1756-RM/
B module.
• Redundant fiber ports for crossloading; no single point of failure of a fiber
cable.
• Plug-and-play-style commissioning and configuration that does not
require extensive programming.
• ControlNet and EtherNet/IP network options for the redundant
chassis pair.
• 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.
• Simple redundant controller configuration by using a checkbox in the
Controller Properties dialog box in RSLogix 5000 software.
• A redundancy system ready to accept commands and monitor the
redundant system states after basic installation, connection, and powerup.
• Switchovers occur as fast as 20 ms.
• Support for these FactoryTalk® applications for EtherNet communication
modules:
– FactoryTalk Alarms and Events
– FactoryTalk Batch
– FactoryTalk PhaseManager™
• Support for CIP Sync technology over an EtherNet/IP network to
establish time coordination across the enhanced redundant system.
• Access to remote I/O modules over an EtherNet/IP network.
• Access to 1715 Redundant I/O systems over an EtherNet/IP network.
• 1756-EN2T socket support.
16 Rockwell Automation Publication 1756-UM535D-EN-P - November 2012
About Enhanced Redundancy Systems Chapter 1
IMPORTANT
Features Not Supported
• Any motion feature
• Any SIL3 functional safety feature within the redundancy controllers
• Firmware Supervisor
• Event Tasks
• Firmware revision 19.052 for 1756-L7x controller
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.
.
Enhanced Redundancy System Components
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 chassis or human-machineinterfaces (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
Chapter 1 About Enhanced Redundancy Systems
I/O 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.
Remote I/O Module Placement Available with Enhanced System, Revision 19.052, 19.053,
EtherNet/IP I/O network
1715 Redundant I/O System
ControlNet network
DeviceNet network
Data Highway Plus
Universal Remote I/O
(1) In an enhanced redundancy system, you can access remote I/O modules on this network only via a ControlNet or EtherNet/IP netwo rk bridge.
(1)
(1)
(1)
or 20.054
Available with Enhanced System, Revision 16.081 or
Earlier
For more information on using remote and 1715 redundant I/O over an
EtherNet network, see I/O Placement on page 44
System User Manual, publication 1715-UM001
and the Redundant I/O
.
18 Rockwell Automation Publication 1756-UM535D-EN-P - November 2012
About Enhanced Redundancy Systems Chapter 1
Enhanced Redundancy System Operations
Once the redundancy modules in the 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:
• Verify that the connection between redundancy modules is ready to
facilitate a switchover
• Verify that the redundant chassis continue to meet qualification
requirements
• 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 other intervals that
you specify.
Rockwell Automation Publication 1756-UM535D-EN-P - November 2012 19
Chapter 1 About Enhanced Redundancy Systems
IMPORTANT
IMPORTANT
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:
• Loss of power
• Major fault on the controller
• Removal or insertion of any module
• Failure of any module
• Damage to a 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.
• 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.
• A program-prompted command to switchover
• 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 these
considerations, see Chapter 7
, Program the Redundant Controller on page 141.
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.
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.
20 Rockwell Automation Publication 1756-UM535D-EN-P - November 2012
About Enhanced Redundancy Systems Chapter 1
IMPORTANT
IMPORTANT
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 updates) is often referred to as ‘HMI Blind Time.’
Beginning with version 20.054, HMI Blind Time due to switchover has been
reduced.
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:
• Quantity and types of tags on scan in RSLinx Enterprise software
• Client screen update rates
• Number of program and controller scope tags in the redundant controller
• Controller loading, which includes the following:
• Number of tasks and scan rates (assumes no continuous task)
• Memory usage
• Null task percentage available
• 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.
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
Chapter 1 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 revisions. 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 1756RMXT 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
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
page 141
.
. You must us e e nhanc ed
on
• 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 functionality 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
Top ic Pa ge
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 Redundanc y Systems 34
ControlNet Networks with Redundant Systems 38
Other Communication Networks 42
Other Communication Networks 42
I/O Placement 44
1715 Redundant I/O Systems 44
Using HMI 46
Firmware Req uirements 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 - November 2012 23
Chapter 2 Design an Enhanced Redundancy System
Components of an Enhanced Redundancy System
The central components of a ControlLogix enhanced redundancy system are
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
module
Chassis 1756-A4 ControlLogix 4-slot chassis
Communication
modules
1756-RM2/A ControlLogix redundancy 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
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
1756-A4LXT ControlLogix-XT™ 4-slot chassis, -25…60 °C (-13…140 °F)
This component is available with enhanced redundancy
systems, revision 19.052 or later.
1756-A5XT ControlLogix-XT 5-slot chassis
1756-A7 ControlLogix 7-slot chassis
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
1756-CN2/B ControlLogix ControlNet bridge module
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
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
31
28
32
24 Rockwell Automation Publication 1756-UM535D-EN-P - November 2012
Design an Enhanced Redundancy System Chapter 2
IMPORTANT
Table 4 - Components Available for Use in a Redundant Chassis Pair
Product Type Cat. No. Description Page
Controllers 1756-L61, 1756-
L62, 1756-L63,
1756-L64
1756-L63XT ControlLogix-XT controller
1756-L65 ControlLogix controller
1756-L72, 1756L73, 1756-L74,
1756-L75
1756-L71 ControlLogix controller
1756-L73XT ControlLogix-XT controller, revision 19.053 or later
Power supplies 1756-PA72, 1756-
PA7 5
1756-PB72, 1756PB75, 1756-PC75,
1756-PH75
1756-PAXT, 1756PBXT
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
ControlLogix controllers
This component is available with enhanced redundancy
systems, revision 19.052 or later.
ControlLogix controllers
This component is available with enhanced redundancy
systems, revision 19.053 or later.
This component is available with enhanced redundancy
systems, revision 20.054 or later.
ControlLogix AC power supplies
ControlLogix DC power supplies
ControlLogix-XT AC power supply
29
34
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
Chapter 2 Design an Enhanced Redundancy System
Redundant Chassis Pair
EtherNet/IP
Switch
1756 ControlLogix I/O
Workstation
1715 Redundant I/O PowerFlex® Drive Connected via
1783-ETAP
1734 POINT I/O™
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
CH2 CH1 OK
2
CH2 CH1 OK
2
26 Rockwell Automation Publication 1756-UM535D-EN-P - November 2012
CH2 CH1 OK
2
CH2 CH1 OK
Redundant Chassis Pair
EtherNet/IP
Switch
1756 ControlLogix I/O
Wor kst ati on
1734 POINT I/O PowerFlex 700S drive connected via
1788-CNCR card
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, Using a ControlNet Network
Rockwell Automation Publication 1756-UM535D-EN-P - November 2012 27
Chapter 2 Design an Enhanced Redundancy System
TIP
01 2 3 0 1 23
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 Tab le 4 on pa ge 24
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:
• Module type
.
CH2 CH1 OK
• Chassis size
• Slot placement
• Firmware revision
• Series level. See page 32.
Figure 3 - Example of Redundant Chassis Pair
CH2 CH1 OK
28 Rockwell Automation Publication 1756-UM535D-EN-P - November 2012
Design an Enhanced Redundancy System Chapter 2
IMPORTANT
Controllers in Redundant Chassis
Remember these points when placing controllers in the redundant chassis pair:
• Controllers are typically included, but not required, in enhanced
redundancy systems.
• 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
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
Unconnected buffer defaults 20 (40, max) 10 (40, max)
Energy Storage Module (ESM) Battery
6 status indicators
status indicators
• 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.
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, use a 1756-L64 controller in the same
chassis as a 1756-L61, 1756-L62, or 1756-L63 controller.
• 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.
• 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
Chapter 2 Design an Enhanced Redundancy System
• 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.
• 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 if it 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 - Cont roller 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
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
Standard Redundancy System or to Another Enhanced Redundancy
System on page 239.
• In an 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
, Upgrade from a
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