Rockwell Automation ControlLogix 5570, ControlLogix 5560 User Manual
ControlLogix 5570/5560 Redundancy
User Manual
Original Instructions
ControlLogix 5570/5560 Redundancy User Manual
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize
themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to
be carried out by suitably trained personnel in accordance with applicable code of practice.
If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be
impaired.
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.
WA RN I NG : 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.
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
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.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential
Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory
requirements for safe work practices and for Personal Protective Equipment (PPE).
2 Rockwell Automation Publication 1756-UM535I-EN-P - October 2020
Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
About ControlLogix
Redundancy Systems
Design a ControlLogix
Redundancy System
Features of the ControlLogix Redundancy System . . . . . . . . . . . . . . . 12
Redundancy System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
I/O Modules in Redundancy Systems . . . . . . . . . . . . . . . . . . . . . . . 14
Redundancy System Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
System Qualification and Synchronization. . . . . . . . . . . . . . . . . . . 15
Switchovers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Chapter 2
Redundant Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Redundant Chassis Configuration Requirements . . . . . . . . . . . . 22
Controllers in Redundant Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Redundancy Modules in Redundant Chassis. . . . . . . . . . . . . . . . . 24
Communication Modules in Redundant Chassis. . . . . . . . . . . . . 25
Power Supplies and Redundant Power Supplies in
Redundancy Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
EtherNet/IP Networks with Redundant Systems . . . . . . . . . . . . . . . . 28
Unicast Functionality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Possible Communication Delays on EtherNet/IP and
ControlNet Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Bridge from an EtherNet/IP Network to a ControlNet
Network. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ControlNet Networks with Redundant Systems . . . . . . . . . . . . . . . . . 30
ControlNet Network Requirements . . . . . . . . . . . . . . . . . . . . . . . . 30
Redundant ControlNet Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Other Communication Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
I/O Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1715 Redundant I/O Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Using HMI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
HMI Connected Via an EtherNet/IP Network . . . . . . . . . . . . . . 38
HMI Connected Via a ControlNet Network . . . . . . . . . . . . . . . . 39
Optional Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 3
Table of Contents
Chapter 3
Install the Redundancy System Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Redundancy System Quick Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Install the Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Install the First Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Install the Redundancy Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Environment and Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Prevent Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal and Insertion Under Power (RIUP) . . . . . . . . . . . . . . . . 47
European Hazardous Location Approval . . . . . . . . . . . . . . . . . . . . 48
Safety-related Programmable Electronic Systems . . . . . . . . . . . . . 48
Optical Ports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Small Form-factor Pluggable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
North American Hazardous Location Approval. . . . . . . . . . . . . . 49
Laser Radiation Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Install the Second Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Connect the Redundancy Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Connect the Fiber-optic Communication Cable to
Redundant Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Connect the Fiber-optic Communication Cable to
Single Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Fiber-optic Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Use Dual Fiber Ports with the 1756-RM2 Redundancy
Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Update Redundant Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Upgrade the Firmware in the First Chassis. . . . . . . . . . . . . . . . . . . 58
Upgrade the Firmware in the Second Chassis . . . . . . . . . . . . . . . . 61
Designate the Primary and Secondary Chassis . . . . . . . . . . . . . . . . . . . 61
After Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Conversion from a Non-redundant to a Redundant System . . . 62
Qualification Status Via the RMCT . . . . . . . . . . . . . . . . . . . . . . . . 63
Reset the Redundancy Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Remove or Replace the Redundancy Module. . . . . . . . . . . . . . . . . 64
Chapter 4
Configure the EtherNet/IP
Network
4 Rockwell Automation Publication 1756-UM535I-EN-P - October 2020
Requested Packet Interval. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
CPU Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
IP Address Swapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Static Versus Dynamic IP Addresses. . . . . . . . . . . . . . . . . . . . . . . . . 68
Reset the IP Address for an EtherNet/IP Communication
Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
CIP Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Produce/Consume Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Table of Contents
Configure EtherNet/IP Communication Modules in a
Redundant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Options for Setting the IP Addresses of EtherNet/IP
Communication Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Half/Full Duplex Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Use a Redundancy System with Device Level Ring . . . . . . . . . . . . . . . 76
Use a Redundancy System with Parallel Redundancy Protocol . . . . 77
Chapter 5
Configure the ControlNet
Network
Configure the Redundancy
Modules
Produce/Consume Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Network Update Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
NUTs with Multiple ControlNet Networks. . . . . . . . . . . . . . . . . 81
Scheduled or Unscheduled Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Use a Scheduled Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Use an Unscheduled Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Add Remote ControlNet Modules While Online . . . . . . . . . . . . 84
Schedule a New Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Update an Existing Scheduled Network . . . . . . . . . . . . . . . . . . . . . . . . . 87
Check the Network Keeper States . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Save the Project for Each Primary Controller . . . . . . . . . . . . . . . . 90
Automatic Keeper Crossloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Chapter 6
About the Redundancy Module Configuration Tool (RMCT). . . . 91
Determine If Further Configuration Is Required. . . . . . . . . . . . . . . . . 92
Use the RMCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Identify the RMCT Version. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Update the RMCT Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Module Info Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Configuration Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Auto-synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Chassis ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Enable User Program Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Redundancy Module Date and Time . . . . . . . . . . . . . . . . . . . . . . . 100
Synchronization Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Commands in the Synchronization Tab . . . . . . . . . . . . . . . . . . . . 102
Recent Synchronization Attempts Log . . . . . . . . . . . . . . . . . . . . . 103
Synchronization Status Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
System Update Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
System Update Commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
System Update Lock Attempts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Locked Switchover Attempts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 5
Table of Contents
Chapter 7
Program the Redundant
Controller
Configure the Redundant Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Enable Time Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Crossloads, Synchronization, and Switchovers . . . . . . . . . . . . . . . . . . 116
Changing Crossload and Synchronization Settings . . . . . . . . . . 116
Default Crossload and Synchronization Settings . . . . . . . . . . . . 117
Recommended Task Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Continuous Task After Switchover . . . . . . . . . . . . . . . . . . . . . . . . 117
Multiple Periodic Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Crossloads and Scan Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Estimate the Crossload Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Redundancy Object Attributes for Crossload Times. . . . . . . . . 121
Equation for Estimating Crossload Times . . . . . . . . . . . . . . . . . . 122
Program to Minimize Scan Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Use a ControlLogix 5570 Controller with a 1756-RM2
Redundancy Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Use Multiple Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Minimize the Number of Programs . . . . . . . . . . . . . . . . . . . . . . . . 124
Manage Tags for Efficient Crossloads . . . . . . . . . . . . . . . . . . . . . . 124
Use Concise Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Program to Maintain Data Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Array (File)/Shift Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Scan-dependent Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Optimize Task Execution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Periodic Task Configuration Optimization . . . . . . . . . . . . . . . . . 135
Continuous Task Configuration Optimization . . . . . . . . . . . . . 137
Change the System Overhead Time Slice . . . . . . . . . . . . . . . . . . . 138
Conduct a Test Switchover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Synchronization After a Switchover. . . . . . . . . . . . . . . . . . . . . . . . 140
Program Logic to Run After a Switchover . . . . . . . . . . . . . . . . . . . . . . 141
Use Messages for Redundancy Commands . . . . . . . . . . . . . . . . . . . . . 142
Verify User Program Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Use an Unconnected Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Configure the MSG Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Set the Task Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Minimum Value for the Watchdog Time . . . . . . . . . . . . . . . . . . . 148
Download the Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Store a Redundancy Project to Nonvolatile Memory . . . . . . . . . . . . 149
Store a Project While the Controller is in Program or
Remote Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Store a Project While a System is Running . . . . . . . . . . . . . . . . . . 151
Load a Project. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Online Edits
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Support for Partial Import Online . . . . . . . . . . . . . . . . . . . . . . . . . 152
Plan for Test Edits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Assemble Edits with Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Reserve Memory for Tags and Logic. . . . . . . . . . . . . . . . . . . . . . . . 158
6 Rockwell Automation Publication 1756-UM535I-EN-P - October 2020
Chapter 8
Table of Contents
Monitor and Maintain a
Redundancy System
Troubleshoot a Redundant
System
Controller Logging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Controller Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Controller Logging in Redundancy Systems . . . . . . . . . . . . . . . . 160
Component Change Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Monitor System Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Verify Date and Time Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Verify System Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Check Qualification Status Via Module Status Displays . . . . . 164
Check Qualification Status Via the RMCT. . . . . . . . . . . . . . . . . 166
Check the EtherNet/IP Module Status . . . . . . . . . . . . . . . . . . . . . . . . 166
EtherNet/IP Module CPU Usage. . . . . . . . . . . . . . . . . . . . . . . . . . 167
EtherNet/IP Module Connections Used . . . . . . . . . . . . . . . . . . . 167
Monitor the EtherNet/IP Network . . . . . . . . . . . . . . . . . . . . . . . . 167
Check the ControlNet Module Status . . . . . . . . . . . . . . . . . . . . . . . . . 168
ControlNet Module CPU Usage . . . . . . . . . . . . . . . . . . . . . . . . . . 169
ControlNet Module Connections Used . . . . . . . . . . . . . . . . . . . . 169
Monitor the ControlNet Network. . . . . . . . . . . . . . . . . . . . . . . . . 169
Chapter 9
General Troubleshooting Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Check the Module Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Use Programming Software to View Errors . . . . . . . . . . . . . . . . . . . . . 173
Redundant Controller Major Fault Codes . . . . . . . . . . . . . . . . . . 175
Use the RMCT for Synchronization Attempts and Status . . . . . . . 176
Recent Synchronization Attempts . . . . . . . . . . . . . . . . . . . . . . . . . 176
Module-level Synchronization Status. . . . . . . . . . . . . . . . . . . . . . . 177
Use the RMCT Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Interpret Event Log Information . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Export All Event Logs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Export Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Contact Rockwell Automation Technical Support . . . . . . . . . . 186
Controller Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Event Log Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Event Classifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Access Extended Information about an Event . . . . . . . . . . . . . . . 190
Interpret Extended Information for an Event . . . . . . . . . . . . . . . 191
Export Event Log Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Clear a Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
System Event History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
System Event History Column Descriptions . . . . . . . . . . . . . . . . 197
Edit a User Comment for a System Event. . . . . . . . . . . . . . . . . . . 198
Save System Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Event Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 7
Table of Contents
Keeper Status Causing Synchronize Failure. . . . . . . . . . . . . . . . . . . . . 201
Check the Module Status Display. . . . . . . . . . . . . . . . . . . . . . . . . . 201
Check Keeper Status in RSNetWorx for ControlNet
Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Valid Keeper Status and Signatures. . . . . . . . . . . . . . . . . . . . . . . . . 202
Partner Network Connection Lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Redundancy Module Connection Lost. . . . . . . . . . . . . . . . . . . . . . . . . 206
Redundancy Module Missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Qualification Aborted Due to a Non-redundant Controller . . . . . 208
Redundancy Module Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . 209
1756-RM2 and 1756-RM2XT Status Indicators . . . . . . . . . . . . 209
1756-RM/A and 1756-RM/B Status Indicators. . . . . . . . . . . . . 213
Redundancy Module Fault Codes and Display Messages . . . . . 216
Recovery Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Appendix A
Convert from a Non-redundant
System
Update the Configuration in Programming Software. . . . . . . . . . . . 220
Replace Local I/O Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
Replace Aliases to Local I/O Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Remove Other Modules from the Controller Chassis. . . . . . . . . . . . 224
Add an Identical Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Upgrade to Redundancy Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Update the Controller Revision and Download the Project . . . . . . 225
Appendix B
Redundancy Object Attributes Table of Redundancy Object Attributes. . . . . . . . . . . . . . . . . . . . . . . . 227
Appendix C
Redundancy System Checklists Chassis Configuration Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Remote I/O Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Redundancy Module Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
ControlLogix Controller Checklist . . . . . . . . . . . . . . . . . . . . . . . . 233
ControlNet Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
EtherNet/IP Module Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Project and Programming Checklist. . . . . . . . . . . . . . . . . . . . . . . . 236
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237
8 Rockwell Automation Publication 1756-UM535I-EN-P - October 2020
Preface
Summary of Changes
Overview
This table contains the changes that are made to this revision.
Top ic Pag e
Added firmware revision 33.051 219, 224
In this publication, ‘ControlLogix Redundancy’ refers to
ControlLogix 5570/5560 Redundancy.
This publication provides this information specific to 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® redundancy system:
• Application engineers
• Control engineers
• Instrumentation technicians
The contents of this publication are for anyone who already has an understanding
of Logix 5000™ control systems, programming techniques, and communication
networks.
Additional Resources
These documents contain additional information concerning related products
from Rockwell Automation.
Table 1 - Additional Documentation
Resource Description
1715 Redundant I/O System Specifications Technical Data, publication 1715-TD001 Contains specifications on a Redundant I/O system.
1756 ControlLogix Controllers Technical Data, publication 1756-TD001 Contains specifications on ControlLogix controllers and redundancy modules.
ControlLogix 5580 Redundant Controller User Manual, publication 1756-UM015
High Availability Systems Reference Manual, publication HIGHAV-RM002
ControlFL ASH Firmware Upgrade Software User Manual, publication 1756-UM105
ControlFLASH Plus Quick Start Guide, publication CFP-QS001C-EN-E
ControlLogix Redundancy Update and Module Replacement Guidelines Reference Manual,
publication 1756-RM010
ControlLogix System Selection Guide, publication 1756-SG001
ControlLogix System User Manual, publication 1756-UM001
Describes how to install, configure, program, operate, and troubleshoot
a ControlLogix® 5580 redundancy system..
Provides information to help design and plan high availability systems.
Describes how to use the ControlFLASH™ software to upgrade device firmware.
Describes how to use the ControlFLASH Plus™ software to upgrade device firmware.
Provides instructions for replacing modules or updating firmware in a powered-up
redundancy system.
Provides information on how to select components for a ControlLogix system.
Contains information on how to install, configure, program, and operate a
ControlLogix system.
Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 9
Preface
Table 1 - Additional Documentation
Resource Description
ControlNet Network Configuration User Manual, publication CNET-UM001 Describes ControlNet® modules and how to use ControlNet modules with a Logix
EtherNet/IP Parallel Redundancy Protocol Application Technique, publication ENET-AT006 Describes how to configure a Parallel Redundancy Protocol (PRP) network with the
EtherNet/IP Device Level Ring Application Technique, publication ENET-AT007 Describes how to install, configure, and maintain linear and Device Level Ring (DLR)
EtherNet/IP Socket Interface Application Technique, publication ENET-AT002 Logix 5000Describes the socket interface that you can use to program MSG
EtherNet/IP Network Devices User Manual, publication ENET-UM006
Integrated Architecture and CIP Sync Configuration Application Technique,
publication IA-AT003
Logix 5000 Controllers Common Procedures Programming Manual,
publication 1756-PM001
Logix 5000 Controllers General Instructions Reference Manual, publication 1756-RM003
Logix 5000 Controllers Information and Status Programming Manual,
publication 1756-PM015
Logix 5000 Controllers I/O and Tag Data Programming Manual, publication 1756-PM004 Provides information on how to access I/O and tag data in Logix 5000 controllers.
Logix 5000 Controllers Major, Minor, and I/O Faults Programming Manual,
publication 1756-PM014
Logix 5000 Controllers Nonvolatile Memory Card Programming Manual,
publication 1756-PM017
Logix 5000 Produced and Consumed Tags Programming Manual,
publication 1756-PM011
Logix 5000 Controllers Quick Start, publication 1756-QS001
Logix 5000 Controllers Tasks, Programs, and Routines Programming Manual,
publication 1756-PM005
PlantPAx DCS Configuration and Implementation User Manual, publication
PROCES-UM100
Using ControlLogix in SIL 2 Applications Safety Reference Manual,
publication 1756-RM001
Redundant I/O System User Manual, publication 1715-UM001
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1
Product Certifications website, rok.auto/certifications
5000 controller.
1756-EN2TP EtherNet/IP™ communication module and a Stratix® 5400 or 5410
switch.
networks that use Rockwell Automation® EtherNet/IP devices with embedded switch
technology.
instructions to communicate bet ween a Logix 5000 controller via an EtherNet/IP
module and Ethernet devices that do not support the EtherNet/IP application
protocol.
Describes how to use EtherNet/IP communication modules with your Logix 5000
controller and communicate with various devices on the Ethernet network.
Provides an explanation of CIP Sync™ technology and how you can synchronize clocks
within the Rockwell Automation Integrated Architecture®.
Provides links to a collection of programming manuals that describe how to use
procedures that are common to all Logix 5000 controllers projects.
This manual provides details about each available instruction for a Logix-based
controller.
Describes how Logix 5000 controllers use connections with other devices.
Describes how to monitor and handle major and minor controller faults.
Provides information on how to access and use a memory card in Logix 5000
controllers.
Provides information to produce and consume system-shared tags and produce a
large array with a Logix 5000 controller.
Provides information to program and maintain Logix 5000 controllers.
Provides information to configure controller tasks and the programs and routines for
the proper execution of these tasks.
Elaborates on the application rules that are required to configure a PlantPAx® system.
Provides safety-related information specific to the use of ControlLogix modules in SIL
2 systems.
Contains information on how to install, configure, program, operate, and
troubleshoot a Redundant I/O system.
Provides general guidelines for installing a Rockwell Automation industrial system.
Provides declarations of conformity, certificates, and other certification details.
You can view or download publications at
http://www.rockwellautomation.com/global/literature-library/overview.page
To order paper copies of technical documentation, contact your local
Allen-Bradley distributor or Rockwell Automation sales representative.
10 Rockwell Automation Publication 1756-UM535I-EN-P - October 2020
.
Chapter 1
About ControlLogix Redundancy Systems
Top ic Pa ge
Features of the ControlLogix Redundancy System 12
Redundancy System Components 13
Redundancy System Operations 15
Restrictions 19
IMPORTANT In this publication, ‘ControlLogix Redundancy’ refers to
ControlLogix 5570/5560 Redundancy.
The ControlLogix® Redundancy System is a system that provides greater
availability. The system has greater availability because it uses a redundant chassis
pair. The redundant chassis pair maintains process operation when events, such as
a fault on a controller, occur that stop process operation on
non-redundant 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 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-UM535I-EN-P - October 2020 11
Chapter 1 About ControlLogix Redundancy Systems
Features of the ControlLogix Redundancy System
The software and hardware components that are required to configure and use a
ControlLogix redundancy system provide these features:
• Redundancy module speeds of up to 1000 Mbps when using a 1756-RM2
module with another 1756-RM2 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.
• The 1756-RM2 and 1756-RM2XT modules are interference-free
regarding safety functions and can be used in ControlLogix SIL 2
applications. See the Using ControlLogix in SIL 2 Applications Safety
Reference Manual, publication 1756-RM001
• 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 or 1756-RM/B
modules.
• Simple redundant controller configuration by using a checkbox in the
Controller Properties dialog box in the Studio 5000 Automation &
Engineering Design Environment® programming 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 FactoryTalk® applications for Ethernet communication
modules including, but not limited to:
– FactoryTalk Alarms and Events
– FactoryTalk Batch
– FactoryTalk PhaseManager™
• Instruction Based Alarms (IBA) considerations:
– 5560 supports up to 250 IBA's with 250 burst
– 5570 supports up to 500 IBA's with 250 burst
– For more information see the Knowledgebase Article, ALMA/ALMD
instructions limits
• Support for CIP Sync™ technology over an EtherNet/IP network to
establish time coordination across the 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.
• Ethernet socket support.
• Support for PhaseManager.
• Supports PRP topologies. See the EtherNet/IP Parallel Redundancy
Protocol Application Technique, publication ENET-AT006
• Supports DLR and topologies. See the EtherNet/IP Device Level Ring
Application Technique, publication ENET-AT007
.
.
.
12 Rockwell Automation Publication 1756-UM535I-EN-P - October 2020
About ControlLogix Redundancy Systems Chapter 1
Features Not Supported
•Any motion feature
• Any SIL 3 functional safety feature within the redundancy controllers
•Firmware Supervisor
• SequenceManager™
•Event Tasks
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 the firmware for your product.
• To obtain signed and unsigned firmware, go to
http://www.rockwellautomation.com/global/support/firmware/
overview.page.
• Once signed firmware is installed, subsequent firmware updates must be
signed also.
There are no functional/feature differences between signed and unsigned
communication modules.
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 - up to seven, optional (any combination)
• At least one controller - up to two controllers in the same family, optional
If the chassis is used as a redundant gateway, then a controller is not
required.
In addition, redundant chassis are connected to other components outside the
redundant chassis pair, for example, remote I/O chassis or human machine
interfaces (HMIs).
For more information about components you can use in a redundancy system, see
Chapter 2
, Design a ControlLogix Redundancy System on page 21.
Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 13
Chapter 1 About ControlLogix Redundancy Systems
I/O Modules in Redundancy Systems
In a redundancy system, you can only use 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 redundancy systems.
Remote I/O Module Placement Available with Redundancy System, Revision 19 and Later Available with Redundancy System, Revision 16 or Earlier
EtherNet/IP I/O network x -
ControlNet network x x
DeviceNet® network
Data Highway Plus™
Universal remote I/O
(1) In a redundancy system, you can access remote I/O modules on this network only via a ControlNet or EtherNet/IP network bridge.
(2) 1756-DHRIO module must be used with a channel configured for RIO.
(1)
(1)
(1)(2)
xx
xx
xx
For more information on how to use remote and 1715 redundant I/O over an
Ethernet network, see I/O Placement on page 36
User Manual, publication 1715-UM001
.
and the Redundant I/O System
14 Rockwell Automation Publication 1756-UM535I-EN-P - October 2020
About ControlLogix Redundancy Systems Chapter 1
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 redundant system is first started, the redundancy modules run checks
on the redundant chassis. These checks 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
–Forced values
–Online edits
–Other project information
Synchronization always takes place immediately following qualification. Also,
depending on your system configuration, synchronization takes place at the end
of each program that is run within the controller project, or at other intervals that
you specify.
Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 15
Chapter 1 About ControlLogix 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:
•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 that is issued via the Redundancy Module Configuration
To ol (R M CT )
After a switchover occurs, the new primary controller continues to execute
programs, which begin 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 116.
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 111.
IMPORTANT During a switchover of the fiber channels of the 1756-RM2 module, scan
time encounters a delay of ~10 ms; however, the chassis always remains
synched.
16 Rockwell Automation Publication 1756-UM535I-EN-P - October 2020
About ControlLogix Redundancy Systems Chapter 1
Data Server Communication Recovery Time Reduction During a Switchover
Brief communication interruption occurs between FactoryTalk Linx software
and the redundant chassis pair when a switchover occurs. After the switchover is
complete, communication resumes automatically.
Data server communication recovery time is the time during a switchover from
primary to secondary, when tag data from the controller is unavailable for reading
or writing. Data server communication recovery time applies to any software that
uses tag data, such as HMI displays, data loggers, alarms systems, or historians.
Data server communication recovery time reduction is important to increase the
availability of the system.
IMPORTANT • Prior to firmware revision 30.051, the communication delays apply only
when communication is exclusively over EtherNet/IP networks.
• With fir mware revision 30.051 or later, the communication delays apply to
both EtherNet/IP and ControlNet networks.
IMPORTANT FactoryTalk Linx 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. Existing and new users who are using FactoryTalk
View version 5.0 (CPR9) or later can use the data server communication
recovery time feature.
As of revision 31.052, the communication delays over Ethernet during a
switchover event have been reduced significantly. When you configure the
connection between a FactoryTalk Linx data server, and a redundant
ControlLogix controller, you can configure redundant shortcut paths to the
primary and secondary controllers. These shortcut paths help reduce data server
communication recovery time that occurs during a redundancy switchover.
The following are required to take advantage of this:
• A dedicated pair of ControlLogix Communication Modules with
firmware revision 11.001 or later (1756-EN2TP, 1756-EN2TR,
1756-EN2T), that do not swap IP addresses. See Do Not Use IP Address
Swapping on page 66.
• ControlLogix 5570 redundancy controllers with redundancy firmware
revision 31.052 or later
• FactoryTalk Linx 6.00 with the FactoryTalk Linx patch available from
Rockwell Automation Knowledgebase Article Patch: FactoryTalk Linx
6.00 patch required to support ControlLogix V31.05 Redundancy, or later
versions of FactoryTalk Linx.
Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 17
Chapter 1 About ControlLogix Redundancy Systems
• Redundant ControlLogix Controller shortcut type in FactoryTalk Linx
that points to the Primary and Secondary controllers through the
communication modules, without swapping IP addresses. For information
on shortcuts in FactoryTalk Linx, see the FactoryTalk Linx Getting Results
Guide, publication LNXENT-GR001
.
18 Rockwell Automation Publication 1756-UM535I-EN-P - October 2020
About ControlLogix Redundancy Systems Chapter 1
Some communication delays can occur during qualification. The existence and
duration of these delays depend on:
• Quantity and types of tags on scan in FactoryTalk Linx software
• Client screen and tag update rates (e.g. FactoryTalk Live Data/FactoryTalk
Historian)
• Number of data subscribers (i.e. FactoryTalk Alarms and Events,
FactoryTalk Batch)
• Size of the application in the redundant controller
• Controller loading, which includes the following:
• Number of tasks and scan rates (assumes no continuous task)
• Number of programs
•Memory usage
• Null task percentage available
•Network traffic
Restrictions
There are restrictions that you must consider when using a redundancy system.
Most of these restrictions apply to all redundancy system revisions. Exceptions
are noted:
• See the release notes of the redundancy bundles for compatible products,
versions, and revisions
• The redundant controller program cannot contain these tasks:
–Event tasks
– Inhibited tasks
For recommendations and requirements that are related to programming
the redundant controller, see Program the Redundant Controller on
page 111.
• You cannot use the Match Project to Controller feature available in Studio
5000 Logix Designer® in a redundancy system.
• You cannot use motion in a redundant controller program.
• You cannot use SequenceManager.
• You cannot use consumed unicast connections in a 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 that remote consumers
consume.
• Outputs controlled by specific instructions are not guaranteed to maintain
a bumpless transition during a switchover. Due to this, it is recommended
to avoid using the following instructions within a redundancy system:
–IOT
–HMIBC
• You can use a maximum of two controllers of the same family, and seven
ControlNet or EtherNet/IP communication modules in each chassis of a
redundant chassis pair.
• You can execute the tasks that were supported previously in a redundancy
system, revision 19.052 or greater.
Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 19
Chapter 1 About ControlLogix Redundancy Systems
01 12 13 24
Catalyst 9300 24S
NETWORK MODULE
C9300-NM-2Q
40G 1
40G 2
01 12 13 24
Catalyst 9300 24S
NETWORK MODULE
C9300-NM-2Q
40G 1
40G 2
01 12 13 24
Catalyst 9300 24S
NETWORK MODULE
C9300-NM-2Q
40G 1
40G 2
01 12 13 24
Catalyst 9300 24S
NETWORK MODULE
C9300-NM-2Q
40G 1
40G 2
This graphic shows an example ControlLogix redundancy system,
revision 19.053 or greater, which uses EtherNet/IP networks.
Figure 1 - Example ControlLogix Redundancy System using an EtherNet/IP Network
20 Rockwell Automation Publication 1756-UM535I-EN-P - October 2020
Chapter 2
Design a ControlLogix Redundancy System
Top ic Pa ge
Redundant Chassis 21
Controllers in Redundant Chassis 22
EtherNet/IP Networks with Redundant Systems 28
ControlNet Networks with Redundant Systems 30
Other Communication Networks 34
I/O Placement 36
Using HMI 38
Optional Software 41
This chapter explains how to use the required and optional components to design
a redundancy system.
Redundant Chassis
IMPORTANT There are module series level, firmware revision, and software version
requirements for redundancy systems.
For more information on these module series level, firmware revision, and
version requirements, see the current release notes at:
http://www.rockwellautomation.com/global/literature-library/
overview.page
You can use any ControlLogix® or ControlLogix-XT™ chassis in a redundant
chassis pair as long as the two chassis that are 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.
TIP When using 1756-L72, 1756-L73, 1756-L74, or 1756-L75 Redundant
controllers in your system, you must use firmware revision 19.053 or greater.
When using a 1756-L71 Redundant controller, you must use firmware
20.054 or greater.
Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 21
Chapter 2 Design a ControlLogix Redundancy System
CH2 CH1 OK
CH2 CH1 OK
1756-L64
1756-L64
01 2 3 0 1 23
Redundant Chassis Configuration Requirements
These configuration parameters must match for the components in a redundant
chassis pair during normal system operation:
•Module type
• Chassis size
• Slot placement
•Firmware revision
•Series level. See page 25
Figure 2 - Example of Redundant Chassis Pair
Controllers in Redundant Chassis
Remember these points when you place controllers in the redundant chassis pair:
• Controllers are typically included, but not required, in redundancy
systems. If you have a redundancy system without controllers, you have
only a redundant gateway rack.
• 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.
The series of the controller in the primary and secondary chassis do not
need to match.
For example, you cannot place a ControlLogix 5560 controller and a
ControlLogix 5570 controller in the same chassis.
IMPORTANT When using a ControlLogix 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.
22 Rockwell Automation Publication 1756-UM535I-EN-P - October 2020
Design a ControlLogix Redundancy System Chapter 2
• You can use different catalog numbers from the same product family in the
same chassis. For example, you can use two ControlLogix 5560 controllers
in a chassis.
• Each ControlLogix 5560/5570 controller must have enough data memory
to store twice the amount of tag data that is associated with a redundant
controller project.
TIP ControlLogix 5580 controllers that are enabled for redundancy do not have
memory constraints.ControlLogix 5580 controllers that are enabled for
redundancy experience no reduction in memory from a standard use
ControlLogix 5580 controller.
• Each controller must have enough I/O memory to store twice the amount
of I/O memory used. To check the I/O memory that is used and available,
access the Memory tab of the Controller Properties dialog box in the
programming software.
For more information about data and I/O memory, see the
Knowledgebase Article Understanding ControlLogix Redundancy Memory
Usage.
• When you use the redundancy system update (RSU) feature to update a
redundancy system while the system continues operation, the updated
controllers must provide the same or greater memory than the existing
controllers.
This table describes the controllers to which you can upgrade, based on the
existing controller that is used, when using RSU.
Existing New 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.
Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 23
Chapter 2 Design a ControlLogix Redundancy System
Plan for Controller Connections
Consider these conditions when you plan controller connection use:
• ControlLogix 5560 controllers provide 250 total connections.
• ControlLogix 5570 controllers provide 500 total 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, which
establishes 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 plugand-play manner without any programming. You connect a redundancy module
pair with the default configuration in the redundant chassis pair and configure
the redundant system.
You can establish redundancy between chassis in either of these manners:
• Insert a redundancy module pair into two powered chassis that contain
redundancy-compliant components and redundancy-enabled application
programs, and then connect the redundancy modules.
• Insert and connect the redundancy modules in two chassis and then insert
redundancy-compliant components into each chassis.
IMPORTANT You are not required to develop any programming to migrate from a non-
redundant to a redundancy system if your application meets these
conditions:
• Your application meets the points that are listed in Restrictions on
page 19.
• The controller properties dialog box in your project has Redundancy
enabled.
Once the redundant chassis pair contains all desired components and is 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.
24 Rockwell Automation Publication 1756-UM535I-EN-P - October 2020
Design a ControlLogix Redundancy System Chapter 2
Communication Modules in Redundant Chassis
Remember these points when placing ControlLogix ControlNet® and
EtherNet/IP™ communication modules in the redundant chassis pair:
• You must use enhanced communication modules in 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. Standard communication modules contain a 'B' in their catalog
number. For example, the 1756-ENBT module.
• You can use the 1756-EN2TR module only with a redundancy system,
revision 19.052 or later.
• You can use the 1756-EN2F module only with a redundancy system,
revision 20.054 or later.
• You can use the 1756-EN2TP module only with a redundancy system,
revision 31.052 or later.
• You can use any combination of up to seven enhanced communication
modules in each redundant chassis.
• If you use a ControlNet network in your redundant chassis pair, you must
have two ControlNet communication modules outside the redundant
chassis pair. When you assign node address numbers, assign the lowest
node number address to a ControlNet communication module outside the
redundant chassis pair.
For more information, see Use at Least Four ControlNet Network Nodes
on page 30 through Assign Lowest Node Numbers to Remote ControlNet
Modules on page 31.
• You cannot use Series A ControlNet communication modules in a
redundancy system.
• The Series for EtherNet/IP communication modules is not required to
match in a partnered set. However, the firmware levels must be the same in
a partnered set. Also, 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.
Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 25
Chapter 2 Design a ControlLogix Redundancy System
• Do not use the USB ports of communication modules to access the
redundant system network while the system is running, that is, online. Use
of the USB ports while online can result in a loss of communication after a
switchover.
Plan for Communication Module Connections
A CIP™ connection is a point-to-point communication mechanism that is used
to transfer data between a producer and a consumer. These mechanisms are
examples of CIP connections:
• Logix 5000™ controller message transfer to Logix 5000 controller
•I/O or produced tag
• Program upload
• RSLinx® DDE/OPC client
• PanelView™ polling of a Logix 5000 controller
ControlLogix ControlNet communication modules provide 131 total CIP
connections. Consider these points when using CIP connections with
ControlLogix ControlNet communication modules:
• 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.
• You can use the remaining 128 CIP connections in any manner that your
application requires, such as the examples listed previously.
ControlLogix EtherNet/IP communication modules provide 259 total CIP
connections. Consider these points when using CIP connections with
ControlLogix EtherNet/IP communication modules:
• Three of the 259 CIP connections are reserved for redundancy.
• You can use the remaining 256 connections in any manner that your
application requires, such as the examples listed previously.
26 Rockwell Automation Publication 1756-UM535I-EN-P - October 2020
Design a ControlLogix Redundancy System Chapter 2
1756-PA75R or 1756-PB75R Power Supplies
Annunciator Wiring (optional)
Power Supplies and Redundant Power Supplies in Redundancy Systems
Redundancy systems can use standard power supplies. You can choose to use
redundant power supplies to maintain power to a ControlLogix chassis if one of
the supplies loses power. Use these hardware components to connect redundant
power supplies:
• Two redundant power supplies for each chassis
• One 1756-PSCA chassis adapter for each redundant chassis
• Two 1756-CPR cables for each redundant chassis to connect the power
supplies to the 1756-PSCA adapter
• Optional, user-supplied annunciator wiring to connect the power supplies
to remote input modules
Figure 3 - Redundant Power Supplies with Redundant Chassis
For more information about redundant power supplies, see the ControlLogix
System Selection Guide, publication 1756-SG001
Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 27
.
Chapter 2 Design a ControlLogix Redundancy System
EtherNet/IP Networks with Redundant Systems
The use of EtherNet/IP networks in a redundancy system is primarily dependent
on your system revision.
IMPORTANT A remote chassis can be accessed over an EtherNet/IP network by using any
EtherNet/IP module that works in a non-redundant chassis with no
additional firmware requirement with the following exception. If the remote
chassis contains a controller that consumes a tag that is produced in the
redundant chassis pair, it can only consume the tag with the required
firmware revisions.
For more information on how to use an EtherNet/IP network in your
redundancy system, see Configure the EtherNet/IP Network on page 65
.
Unicast Functionality
Redundancy systems support unicast produced tags. Unicast consumed tags are
not supported in redundancy systems. Unicast I/O is not supported in a
redundancy system.
Possible Communication Delays on EtherNet/IP and ControlNet Networks
The connection between a component and the redundant chassis pair can
experience brief communication delays during a switchover. After the switchover
is complete, communication resumes automatically.
These connection types can experience the communication delay when the
switchover occurs:
• HMI to redundant chassis pair
• FactoryTalk® Batch server to redundant chassis pair
• FactoryTalk Alarms and Events Service to redundant chassis pair
IMPORTANT • Prior to firmware revision 30.051, the communication delays apply only
when communication is exclusively over EtherNet/IP networks.
• With fir mware revision 30.051 or later, the communication delays apply to
both EtherNet/IP and ControlNet networks.
28 Rockwell Automation Publication 1756-UM535I-EN-P - October 2020
Design a ControlLogix Redundancy System Chapter 2
ControlNe t
EtherNet/IP
HMI
Redundant Chassis Pair
Bridge from an EtherNet/IP Network to a ControlNet Network
Bridge from an EtherNet/IP network to a ControlNet network if you must
maintain the connection between the component and a redundant chassis pair
during a switchover.
IMPORTANT You can bridge from an EtherNet/IP network to a ControlNet network to
maintain the connection between the component and a redundant chassis
only in redundancy firmware revisions prior to revision 30.051.
I/O connections are not supported in any bridge configurations in any
version.
See Data Server Communication Recovery Time Reduction During a
Switchover on page 17.
This example graphic shows 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 and the EtherNet/IP and
ControlNet communication modules. The I/O modules are not required and are
shown for example only. For all requirements, see ControlNet Networks with
Redundant Systems on page 30.
Figure 4 - Configuration Used to Eliminate Communication Delays on Switchover
CH2 CH1 OK
CH2 CH1 OK
Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 29
Chapter 2 Design a ControlLogix Redundancy System
ControlNet Networks with Redundant Systems
ControlNet networks are used to connect redundant controller chassis to remote
I/O and to other devices in the system.
IMPORTANT A remote chassis can be accessed over a ControlNet network that uses any
ControlNet module that works in a non-redundant chassis with no
additional firmware requirement.
ControlNet Network Requirements
If you use a ControlNet network in your redundancy system, you must
consider the following:
• Use at Least Four ControlNet Network Nodes
• Assign Lowest Node Numbers to Remote ControlNet Modules
• Set Partnered ControlNet Module Switches to the Same Address
• 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
per ControlNet network. This configuration is required because two or more
ControlNet nodes must be used with the two ControlNet modules that are 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 fewer than four nodes, and a switchover occurs,
connections can drop and outputs connected to that node can change state
during the switchover.
You can include these ControlNet modules and redundant ControlNet nodes:
• ControlNet bridges in remote chassis
• Any other ControlNet devices on the ControlNet network
• A workstation running RSLinx Classic communication software that is
connected via a ControlNet network
For more information, see Knowledgebase Article ControlNet Network Keeper
and ControlLogix Redundancy.
30 Rockwell Automation Publication 1756-UM535I-EN-P - October 2020
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