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.
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.
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).
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Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 |
Table of Contents
About ControlLogix
Redundancy Systems
Design a ControlLogix
Redundancy System
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
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 |
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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
Configure the EtherNet/IP
Network
Chapter 4
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
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Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 |
Table of Contents
Configure the ControlNet
Network
Configure the Redundancy
Modules
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
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
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Table of Contents
Program the Redundant
Controller
Chapter 7
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
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Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 |
Table of Contents
Monitor and Maintain a
Redundancy System
Troubleshoot a Redundant
System
Chapter 8
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
Convert from a Non-redundant System
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
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 |
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ControlLogix Controller Checklist . . . . . . . . . . . . . . . . . . . . . . . . |
233 |
|
ControlNet Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . |
234 |
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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
This table contains the changes that are made to this revision.
Topic |
Page |
|
|
Added firmware revision 33.051 |
219, 224 |
|
|
Overview
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
Additional Resources
The contents of this publication are for anyone who already has an understanding of Logix 5000™ control systems, programming techniques, and communication networks.
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 |
Describes how to install, configure, program, operate, and troubleshoot |
|
a ControlLogix® 5580 redundancy system.. |
|
|
High Availability Systems Reference Manual, publication HIGHAV-RM002 |
Provides information to help design and plan high availability systems. |
|
|
ControlFLASH Firmware Upgrade Software User Manual, publication 1756-UM105 |
Describes how to use the ControlFLASH™ software to upgrade device firmware. |
|
|
ControlFLASH Plus Quick Start Guide, publication CFP-QS001C-EN-E |
Describes how to use the ControlFLASH Plus™ software to upgrade device firmware. |
|
|
ControlLogix Redundancy Update and Module Replacement Guidelines Reference Manual, |
Provides instructions for replacing modules or updating firmware in a powered-up |
publication 1756-RM010 |
redundancy system. |
|
|
ControlLogix System Selection Guide, publication 1756-SG001 |
Provides information on how to select components for a ControlLogix system. |
|
|
ControlLogix System User Manual, publication 1756-UM001 |
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 |
||
|
|
|
5000 controller. |
|
|
||
EtherNet/IP Parallel Redundancy Protocol Application Technique, publication ENET-AT006 |
Describes how to configure a Parallel Redundancy Protocol (PRP) network with the |
||
|
|
|
1756-EN2TP EtherNet/IP™ communication module and a Stratix® 5400 or 5410 |
|
|
|
switch. |
|
|
||
EtherNet/IP Device Level Ring Application Technique, publication ENET-AT007 |
Describes how to install, configure, and maintain linear and Device Level Ring (DLR) |
||
|
|
|
networks that use Rockwell Automation® EtherNet/IP devices with embedded switch |
|
|
|
technology. |
|
|
||
EtherNet/IP Socket Interface ApplicationTechnique, publication ENET-AT002 |
Logix 5000Describes the socket interface that you can use to program MSG |
||
|
|
|
instructions to communicate between a Logix 5000 controller via an EtherNet/IP |
|
|
|
module and Ethernet devices that do not support the EtherNet/IP application |
|
|
|
protocol. |
|
|
||
EtherNet/IP Network Devices User Manual, publication ENET-UM006 |
Describes how to use EtherNet/IP communication modules with your Logix 5000 |
||
|
|
|
controller and communicate with various devices on the Ethernet network. |
|
|
||
Integrated Architecture and CIP Sync Configuration Application Technique, |
Provides an explanation of CIP Sync™ technology and how you can synchronize clocks |
||
publication IA-AT003 |
within the Rockwell Automation Integrated Architecture®. |
||
|
|
||
Logix 5000 Controllers Common Procedures Programming Manual, |
Provides links to a collection of programming manuals that describe how to use |
||
publication 1756-PM001 |
procedures that are common to all Logix 5000 controllers projects. |
||
|
|
||
Logix 5000 Controllers General Instructions Reference Manual, publication 1756-RM003 |
This manual provides details about each available instruction for a Logix-based |
||
|
|
|
controller. |
|
|
||
Logix 5000 Controllers Information and Status Programming Manual, |
Describes how Logix 5000 controllers use connections with other devices. |
||
publication 1756-PM015 |
|
||
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|
||
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, |
Describes how to monitor and handle major and minor controller faults. |
||
publication 1756-PM014 |
|
||
|
|
||
Logix 5000 Controllers Nonvolatile Memory Card Programming Manual, |
Provides information on how to access and use a memory card in Logix 5000 |
||
publication 1756-PM017 |
controllers. |
||
|
|
||
Logix 5000 Produced and Consumed Tags Programming Manual, |
Provides information to produce and consume system-shared tags and produce a |
||
publication 1756-PM011 |
large array with a Logix 5000 controller. |
||
|
|
||
Logix 5000 Controllers Quick Start, publication 1756-QS001 |
Provides information to program and maintain Logix 5000 controllers. |
||
|
|
||
Logix 5000 Controllers Tasks, Programs, and Routines Programming Manual, |
Provides information to configure controller tasks and the programs and routines for |
||
publication 1756-PM005 |
the proper execution of these tasks. |
||
|
|
||
PlantPAx DCS Configuration and Implementation User Manual, publication |
Elaborates on the application rules that are required to configure a PlantPAx® system. |
||
PROCES-UM100 |
|
||
|
|
||
Using ControlLogix in SIL 2 Applications Safety Reference Manual, |
Provides safety-related information specific to the use of ControlLogix modules in SIL |
||
publication 1756-RM001 |
2 systems. |
||
|
|
||
Redundant I/O System User Manual, publication 1715-UM001 |
Contains information on how to install, configure, program, operate, and |
||
|
|
|
troubleshoot a Redundant I/O system. |
|
|
||
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 |
Provides general guidelines for installing a Rockwell Automation industrial system. |
||
|
|
||
Product Certifications website, rok.auto/certifications |
Provides declarations of conformity, certificates, and other certification details. |
||
|
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|
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
Topic |
Page |
|
|
Features of the ControlLogix Redundancy System |
12 |
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|
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 |
|
|
Redundancy System
Components
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.
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(1) |
x |
x |
Data Highway Plus™(1) |
x |
x |
Universal remote I/O(1)(2) |
x |
x |
(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.
For more information on how to use remote and 1715 redundant I/O over an
Ethernet network, see I/O Placement on page 36 and the Redundant I/O System
User Manual, publication 1715-UM001.
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 Tool (RMCT)
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 firmware 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 |
|
|
Restrictions
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
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
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 |
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Rockwell Automation Publication 1756-UM535I-EN-P - October 2020 |
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|||||||||||||||||||||||||||||||
Chapter 2
Design a ControlLogix Redundancy System
Redundant Chassis
Topic |
Page |
|
|
Redundant Chassis |
21 |
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Controllers in Redundant Chassis |
22 |
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EtherNet/IP Networks with Redundant Systems |
28 |
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ControlNet Networks with Redundant Systems |
30 |
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Other Communication Networks |
34 |
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I/O Placement |
36 |
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Using HMI |
38 |
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Optional Software |
41 |
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This chapter explains how to use the required and optional components to design a redundancy system.
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
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
0 |
1 |
2 |
3 |
0 |
1 |
2 |
3 |
CH2 CH1 OK |
| <![if ! IE]> <![endif]>1756-L64 |
CH2 CH1 OK |
| <![if ! IE]> <![endif]>1756-L64 |
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 plug- and-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 nonredundant 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 |
|
|
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
1756-PA75R or 1756-PB75R Power Supplies
Annunciator Wiring (optional)
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 firmware 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 |
|
|
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
HMI
EtherNet/IP
ControlNet
Redundant Chassis Pair
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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