Rockwell Automation ControlLogix 5580 User Manual

ControlLogix 5580 Redundant

Controller

For Use in High Availability Systems

User Manual

Original Instructions

ControlLogix 5580 Redundant Controller 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).

2	Rockwell Automation Publication 1756-UM015B-EN-P - February 2021

ControlLogix 5580 High

Availability Systems

Configure the Redundancy

System

Configure the EtherNet/IP

Network

Table of Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1

Features of the ControlLogix 5580 High Availability System . . . . . . . . . 12

Controller Keyswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Redundancy System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

I/O Modules in Redundancy Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Fiber-optic Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Use Dual Fiber Ports with the 1756-RM2 Redundancy Module . . . . 15

Redundancy System Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

System Qualification and Synchronization. . . . . . . . . . . . . . . . . . . . . 17

Switchovers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Chapter 2

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Download the Redundancy Firmware Bundle . . . . . . . . . . . . . . . . . . . . . . 22 Install the Firmware Bundle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install the Redundancy Module Configuration Tool . . . . . . . . . . . . . . . . 22 Install the Redundancy System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Configure Redundant Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Upgrade the Firmware in the First Chassis . . . . . . . . . . . . . . . . . . . . . 24 Upgrade the Firmware in the Second Chassis . . . . . . . . . . . . . . . . . . 25 Set the initial Primary and Secondary Chassis . . . . . . . . . . . . . . . . . . . . . 25 After Designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Conversion from a Non-redundant to a Redundant System. . . . . . 26 Qualification Status Via the RMCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Reset the Redundancy Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Remove or Replace the Redundancy Module . . . . . . . . . . . . . . . . . . . 28

Chapter 3

Requested Packet Interval (RPI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 IP Address Swapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Static Versus Dynamic IP Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Reset the IP Address for an EtherNet/IP Communication Module 32 CIP Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Produce/Consume Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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3

Table of Contents

Configure the Redundancy

Modules

Configure the Redundant

Controller

Configure EtherNet/IP Communication Modules in a Redundant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Options for Setting the IP Addresses of EtherNet/IP Communication Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Half/Full Duplex Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Use a Redundancy System with Device Level Ring . . . . . . . . . . . . . . . . . . 38 Use a Redundancy System with Parallel Redundancy Protocol . . . . . . . 38

Chapter 4

Determine If Further Configuration Is Required . . . . . . . . . . . . . . . . . . . 40

Configure the Redundancy Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Identify the RMCT Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Module Info Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Configuration Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Auto-synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Chassis ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Enable User Program Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Redundancy Module Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Synchronization Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Commands in the Synchronization Tab. . . . . . . . . . . . . . . . . . . . . . . . 48

Recent Synchronization Attempts Log . . . . . . . . . . . . . . . . . . . . . . . . . 48

Synchronization Status Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

System Update Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

System Update Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

System Update Lock Attempts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Locked Switchover Attempts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Chapter 5

Configure the Redundant Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Enable Time Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Crossloads, Synchronization, and Switchovers. . . . . . . . . . . . . . . . . . . . . 61 Changing Crossload and Synchronization Settings . . . . . . . . . . . . . 61 Default Crossload and Synchronization Settings . . . . . . . . . . . . . . . 62 Recommended Task Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Continuous Task After Switchover . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Multiple Periodic Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Crossloads and Scan Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Estimate the Crossload Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Redundancy Object Attributes for Crossload Times . . . . . . . . . . . . . 66 Equation for Estimating Crossload Times. . . . . . . . . . . . . . . . . . . . . . 67 Set the Task Watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Minimum Value for the Watchdog Time . . . . . . . . . . . . . . . . . . . . . . . 69

4	Rockwell Automation Publication 1756-UM015B-EN-P - February 2021

Table of Contents

	Chapter 6
Programming Best Practices	Program to Minimize Scan Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 71
	Minimize the Number of Programs . . . . . . . . . . . . . . . . . . . . . . . . . .	. 72
	Manage Tags for Efficient Crossloads . . . . . . . . . . . . . . . . . . . . . . . . .	73
	Use Concise Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	75
	Program to Maintain Data Integrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	76
	Timer Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	76
	Array (File)/Shift Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	77
	Scan-dependent Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	78
	Optimize Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	80
	Programming Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	81
	Data Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	81
	SSV Instruction Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	81
	Communications Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	81
	Programed-scoped Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	82
	Redundant System Update (RSU) Operation . . . . . . . . . . . . . . . . . . .	82
	Instruction Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	82
	Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	83
	Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	83
	Conduct a Test Switchover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	84
	Synchronization After a Switchover . . . . . . . . . . . . . . . . . . . . . . . . . . .	85
	Program Logic to Run After a Switchover. . . . . . . . . . . . . . . . . . . . . . . . . .	86
	Use Messages for Redundancy Commands . . . . . . . . . . . . . . . . . . . . . . . .	87
	Verify User Program Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	87
	Use an Unconnected Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	87
	Configure the MSG Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	88
	Download the Project. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	90
	Store a Redundancy Project to Nonvolatile Memory . . . . . . . . . . . . . . . .	91
	Store a Project While the Controller is in Program or Remote
	Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	91
	Store a Project While a System is Running . . . . . . . . . . . . . . . . . . . . .	92
	Load a Project . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	93
	Online Edits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	94
	Partial Import Online (PIO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	94
	Plan for Test Edits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	95
	Assemble Edits with Caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	96
	Chapter 7
Monitor and Maintain a	Controller Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	99
Redundancy System	Controller Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	99
	Controller Logging in Redundancy Systems . . . . . . . . . . . . . . . . . . .	100
	Component Change Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	100
	Monitor System Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	100
	Verify Date and Time Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	102
	Verify System Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	103
	Check Qualification Status Via Module Status Displays . . . . . . . .	103
	Check Qualification Status Via the RMCT . . . . . . . . . . . . . . . . . . . . .	105

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5

Table of Contents

Troubleshoot a Redundant

System

Check the EtherNet/IP Module Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

CPU Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Connections Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Chapter 8

General Troubleshooting Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Check the Module Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 Use Programming Software to View Errors . . . . . . . . . . . . . . . . . . . . . . . 109 Redundant Controller Major Fault Codes . . . . . . . . . . . . . . . . . . . . . . 111 Use the RMCT for Synchronization Attempts and Status. . . . . . . . . . . . 111 Recent Synchronization Attempts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Module-level Synchronization Status . . . . . . . . . . . . . . . . . . . . . . . . . 112 Use the RMCT Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Controller Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Event Classifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Access Extended Information about an Event . . . . . . . . . . . . . . . . . 116 Interpret Extended Information for an Event . . . . . . . . . . . . . . . . . 117 Interpret Event Log Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Export Event Log Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Export Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Contact Rockwell Automation Technical Support . . . . . . . . . . . . . . 127 Clear a Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 System Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 System Event History Column Descriptions. . . . . . . . . . . . . . . . . . . 129 Edit a User Comment for a System Event . . . . . . . . . . . . . . . . . . . . . 130 Save System Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 Event Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Partner Network Connection Lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Redundancy Module Connection Lost. . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Redundancy Module Missing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Qualification Aborted Due to a Non-redundant Controller . . . . . . . . . 136 Redundancy Module Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 1756-RM2 and 1756-RM2XT Status Indicators. . . . . . . . . . . . . . . . . . 138 Redundancy Module Fault Codes and Display Messages . . . . . . . . 141 Recovery Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Convert from a Non-redundant System

Appendix A

Update the Configuration in Programming Software. . . . . . . . . . . . . . 144 Replace Local I/O Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Replace Aliases to Local I/O Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Remove Other Modules from the Controller Chassis. . . . . . . . . . . . . . . 148 Add an Identical Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Upgrade to Redundancy Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Update the Controller Revision and Download the Project . . . . . . . . . 148

	Appendix B
Redundancy Object Attributes	Table of Redundancy Object Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . .	149

6	Rockwell Automation Publication 1756-UM015B-EN-P - February 2021

Table of Contents

Appendix C

Redundancy System Checklists Chassis Configuration Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Remote I/O Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Redundancy Module Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

ControlLogix Controller Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

EtherNet/IP Module Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Project and Programming Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Online Firmware Update

Considerations

Appendix D

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 RSU Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Redundancy System Update Migration Paths . . . . . . . . . . . . . . . . . 156 Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Verify Your Redundancy Module Configuration Tool (RMCT) Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Prepare the Controller Project for the Update . . . . . . . . . . . . . . . . . . . . . 158 Update the Redundancy System Firmware . . . . . . . . . . . . . . . . . . . . . . . 159 Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Prepare the Redundant Chassis for the Firmware Update. . . . . . . 160

Update the Redundancy Module Firmware in the

Primary Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Update Redundancy Module Firmware and Other

Module Firmware in the Secondary Chassis . . . . . . . . . . . . . . . . . . . 162 Lock the System and Initiate a Switchover to Update. . . . . . . . . . . 163 Update the New Secondary Chassis Firmware . . . . . . . . . . . . . . . . . 165 Synchronize the Redundant Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . 165 EDS Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Module Replacement

Considerations

Appendix E

Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Replace a Module in the Secondary Chassis That Has the

Same Catalog Number and Firmware Revision . . . . . . . . . . . . . . . . . . . 170 Replace an EtherNet/IP Module with a New Series . . . . . . . . . . . . . . . . 171 Synchronization and Switchover for EtherNet/IP Modules . . . . . 171 Replace a 1756-RM2 Module with a 1756-RM2 Module . . . . . . . . . . . . . . 174

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

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Table of Contents

Notes:

8	Rockwell Automation Publication 1756-UM015B-EN-P - February 2021

Preface

Catalog Numbers

Summary of Changes

Overview

This publication applies to these controllers:

•1756-L81E, 1756-L81EK,1 756-L81E-NSE, 1756-L81EXT, 1756-L81EP

•1756-L82E, 1756-L82EK, 1756-L82E-NSE, 1756-L82EXT

•1756-L83E, 1756-L83EK, 1756-L83E-NSE, 1756-L83EXT, 1756-L83EP

•1756-L84E, 1756-L84EK, 1756-L84E-NSE, 1756-L84EXT

•1756-L85E, 1756-L85EK, 1756-L85E-NSE, 1756-L85EXT, 1756-L85EP

This manual contains new and updated information. This list includes substantive updates only and is not intended to reflect all changes.

Topic	Page
Added Online Firmware Update Considerations.	155
Added Module Replacement Considerations.	169

This publication provides information specific to ControlLogix 5580 high availability systems:

•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.

	Resource	Description
	High Availability System Reference Manual, publication HIGHAV-RM002	Provides information to help design and plan high availability systems.
	ControlLogix 5580 and GuardLogix 5580 Controllers User Manual, publication 1756-	Provides information on how to configure, select I/O modules, manage
		communication, develop applications, and troubleshoot the ControlLogix 5580
	UM543
		controllers.
	ControlLogix 5580 Controllers Installation Instructions, publication 1756-IN043	Describes how to install ControlLogix 5580 controllers.
	ControlLogix Redundancy Modules Installation Instructions, publication 1756-IN087.	Describes how to install ControlLogix redundancy modules.
	1756 EtherNet/IP Communication Modules Installation Instructions,	Describes how to install ControlLogix EtherNet/IP communication modules.
	publication 1756-IN050
	ControlLogix Power Supply Installation Instructions, publication 1756-IN619	Describes how to install standard power supplies.
	ControlLogix Redundant Power Supply Installation Instructions, publication 1756-IN620	Describes how to install redundant power supplies.
	ControlLogix Chassis Installation Instructions, publication 1756-IN621	Describes how to install ControlLogix chassis.

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Preface

	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.
	ControlFLASH Plus Quick Start Guide, publication CFP-QS001C-EN-E	Describes how to use the ControlFLASH Plus™ software to upgrade device
		firmware.
	ControlLogix System Selection Guide, publication 1756-SG001	Provides information on how to select components for a ControlLogix system.
	EtherNet/IP Parallel Redundancy Protocol Application Technique, publication ENET-	Describes how to configure a Parallel Redundancy Protocol (PRP) network with the
		1756-EN2TP EtherNet/IP™ communication module and a Stratix® 5400 or 5410
	AT006
		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.
		Logix 5000Describes the socket interface that you can use to program MSG
	EtherNet/IP Socket Interface Application Technique, publication ENET-AT002	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 Configuration 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
	publication IA-AT003	clocks 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.
	PlantPAx Process Automation System Reference Manual, publication PROCES-UM001	Elaborates on the application rules that are required to configure a PlantPAx®
		system.
	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.

You can view or download publications at rok.auto/literature.

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Chapter 1

ControlLogix 5580 High Availability Systems

Topic	Page
Features of the ControlLogix 5580 High Availability System	12
Controller Keyswitch	13
Redundancy System Components	14
Fiber-optic Cable	15
Redundancy System Operations	17
Restrictions	19

The ControlLogix® 5580 high availability system uses a redundant chassis pair to maintain process operation when events occur that stop process operation on non-redundant systems, such as a fault on a controller.

The redundant chassis pair includes two synchronized ControlLogix chassis with specific, identical components in each. For example, one redundancy module and at least one 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.

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Chapter 1 ControlLogix 5580 High Availability Systems

Features of the

ControlLogix 5580 High

Availability System

The software and hardware components that are required to configure and use a ControlLogix 5580 high availability system provide these features:

•All non-safety ControlLogix 5580 controller catalog numbers are supported.

•ControlLogix 5580 redundant controllers use the same controller firmware revision as standard controllers.

•Configure a redundant controller with a checkbox on the Controller Properties dialog box in Studio 5000 Logix Designer application software.

•Partnered sets of 1756-RM2 modules can reach speeds as fast as 1000 Mbps.

•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.

•Support for produced unicast connections.

•EtherNet/IP network for the redundant chassis pair.

•Support for Device-level Ring (DLR) and Parallel Redundancy Protocol (PRP) networks.

•Easy-to-use, fiber-optic communication cable that connects redundant chassis pairs.

•A redundancy system ready to command 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™

•Logix tag-based alarms considerations:

-ControlLogix 5580 controllers support up to 7500 Logix tag-based alarms per software guidelines.

•Logix instruction-based alarms considerations:

-ControlLogix 5580 controllers support up to 3000 Logix instructionbased alarms with 3000 burst.

•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.

•Supports FLEX 5000 I/O.

•Supports PhaseManager.

•Supports DLR topologies with the use of an EtherNet/IP communication module. For more information about DLR, see the EtherNet/IP Device Level Ring Application Technique, publication ENET-AT007.

•Sockets are supported in the 1756-EN2T, 1756-EN2TP, 1756-EN2TR and 1756-EN2F modules, firmware revision 5.008 or later. For additional information, see the EtherNet/IP Socket Interface Application Technique, publication ENET-AT002.

•For information on how to best organize a process application, see the PlantPAx DCS Configuration and Implementation User Manual publication PROCES-UM100.

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Controller Keyswitch

Chapter 1 ControlLogix 5580 High Availability Systems

Features Not Supported

•Compact 5000 I/O

•The embedded Gigabit Ethernet port of the controller.

•DeviceNet(1), ControlNet, RIO, DH+ networks

•Messaging to PLC2, PLC3, PLC5, SLC, and other legacy controllers.

•IEC62443-4-2 secure communications

•License-based Source and Execution Protection

•Any motion feature

•Firmware Supervisor

•Event Tasks

•Input or consumed unicast connections

•SequenceManager

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.

The position of the keyswitch on the controllers in both chassis must match (both in REM or both in RUN). There should NOT be a mismatch. See Knowledgebase Technote Processor Key Switches in ControlLogix Redundancy System.

For more information on operation modes of the controller see Choose the Controller Operation Mode in the ControlLogix 5580 and GuardLogix 5580 Controllers User Manual, publication 1756-UM543.

(1)DeviceNet modules are supported if accessed across an Ethernet bridge but may experience a bump during a ControlLogix Redundancy switchover.

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Chapter 1 ControlLogix 5580 High Availability Systems

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 1756-RM2 redundancy module - Required

Redundancy modules link the redundant chassis pair to monitor events in each chassis and initiate system responses as required.

•At least one ControlLogix EtherNet/IP communication module - up to seven, optional (any combination)

•One ControlLogix 5580 controller.

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 the High Availability System Reference Manual, publication HIGHAV-RM002.

I/O Modules in Redundancy Systems

A ControlLogix 5580 redundancy system supports I/O modules in a remote chassis connected via EtherNet/IP. You cannot use I/O modules in the redundant chassis pair.

You can put DeviceNet modules in a remote rack but DeviceNet devices will not be bumpless during a switchover event.

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Fiber-optic Cable

Chapter 1 ControlLogix 5580 High Availability Systems

If you choose to make your own fiber-optic cables, consider the following:

•Fiber-optic Communication Cable Specifications:

	Attribute	1756-RM2	1756-RM2XT
	Temperature, operating	0…60 °C (32…140 °F)	-25…70 °C (-13…158 °F)
	Connector type	LC-type (fiber-optic)
	Cable type	8.5/125 micron single-mode fiber-optic cable
	Channels	1 (transmit and receive fiber)
	Length, max	10 km (10,000 m, 10936.13 yd
	Transmission	1000 Mbps
	Wavelength	1310 nm
	SFP transceiver	Transceiver Rockwell Automation PN-91972
		Connector/cable: LC duplex connector, 1000BASE-LX-compliant

•Determine Optical Power Budget

You can determine the maximum optical-power budget in decibels (dB) for a fiber-optic link by computing the difference between the minimum transmitter-output optical power (dBm avg) and the lowest receiver sensitivity (dBm avg). As shown in Table 1 , the maximum optical power budget for the 1756-RM2 module is -9.5 - (-19) or 9.5 dB.

The optical-power budget provides the necessary optical-signal range to establish a working fiber-optic link. You must account for the cable lengths and the corresponding link penalties. All penalties that affect the link performance must be accounted for within the link optical power budget.

Table 1 - Optical Power Budget Ranges for 1756-RM2 and 1756-RM2XT Modules

Transmitter	Min	Typical	Max	Unit
Output optical power	-9.5	—	-3	dBm
Wavelength	1270	—	1355	nm
Receiver	Min	Typical	Max	Unit
Receiver sensitivity	—	—	-19	dBm
Receiver overload	—	—	-3	dbm
Input operating wavelength	1270	—	1355	nm

Use Dual Fiber Ports with the 1756-RM2 Redundancy Module

The dual fiber ports of the 1756-RM2 module constitute a redundant pair of communication channels between the partner 1756-RM2 modules in a redundant chassis pair. One of the channels is termed as 'ACTIVE', while the other channel is termed as 'REDUNDANT'. All data communication between the partner redundancy modules is conducted exclusively over the ACTIVE channel. If or when the ACTIVE channel fails, a 'Fiber Channel Switchover' is initiated automatically and all data communication shifts to the REDUNDANT channel, which then becomes the new ACTIVE channel.

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Chapter 1 ControlLogix 5580 High Availability Systems

Fiber Channel Switchover

Due to the fiber channel switchover, the redundant chassis pair remains synchronized even after a failure of the ACTIVE channel. Any of the following failures of the ACTIVE channel trigger an automatic fiber channel switchover to the REDUNDANT channel, provided the REDUNDANT channel is still operating in a normal condition:

•Signal attenuation along the fiber cable path that is routed between the partner redundancy modules

•A broken or damaged fiber cable that is routed between the partner redundancy modules

•Improper or loosely fit cable connector

•SFP transceiver fault

•Removal or loose connection of the SFP transceiver

•Data communication error (signaled by a failed CRC check)

Chassis synchronization is lost only when both of the channels have failed or are disconnected.

The fiber channel switchover can occasionally extend the completion of data communication packets between the partner redundancy modules. Therefore, the scan time of the controller can occasionally experience a delay of 10 ms or less.

Configuration

The use of dual fiber ports is entirely ‘plug and play’. There is no user configuration that is needed for any of the operations of the active and redundant channels. The firmware automatically manages the selection of active and redundant channels. The dual fiber cables between the partner redundancy modules can be crossed over between CH1 and CH2 without any restriction, however, this is not recommended as it can complicate troubleshooting.

Monitoring and Repair

Synchronization is preserved if the REDUNDANT channel has failed or is being repaired. The repair of the REDUNDANT channel can be performed online while the redundant chassis pair is running synchronized. To aid online repairs, the fiber cable connections and SFP transceiver can be removed and inserted under power.

It is not mandatory to use the REDUNDANT channel that is connected between the two redundancy modules. The redundant chassis pair can be synchronized with just one of the channels connected. The REDUNDANT channel can be installed later while the chassis is running synchronized.

The status indicators on the front panel and the indicators and counters that are displayed in the RMCT provide monitoring of the channel status.

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Redundancy System

Operations

Chapter 1 ControlLogix 5580 High Availability Systems

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.

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 (for example, FactoryTalk Live Data/ FactoryTalk Historian)

•Number of data subscribers (for example, FactoryTalk Alarms and Events, FactoryTalk Batch, and so on)

•Size of the redundant controller application

•Network traffic

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Chapter 1 ControlLogix 5580 High Availability 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

•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. For more information about how tasks execute after a switchover, see Crossloads, Synchronization, and Switchovers on page 61.

IMPORTANT It is required that all messaging communications point to the primary controller when reading/writing to a ControlLogix Redundancy system. Do not target message instructions to modules in the secondary chassis.

Your application can require some programming considerations and potential changes to accommodate a switchover. For more information on these considerations, see Chapter 6, Programming Best Practices on page 71.

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.

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.

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.

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Restrictions

Chapter 1 ControlLogix 5580 High Availability Systems

The following are required to take advantage of this:

•A dedicated pair of ControlLogix communication modules with firmware revision 11.002 or later (1756-EN2TP, 1756-EN2TR, 1756-EN2T), that do not swap IP addresses. See Do Not Use IP Address Swapping on page 30.

•ControlLogix 5580 redundancy controllers with redundancy firmware revision 33.011 or later

•FactoryTalk Linx 6.00 with the FactoryTalk Linx patch available from Knowledgebase Technote Patch: FactoryTalk Linx 6.00 patch required to support ControlLogix V31.05 Redundancy, or later versions of FactoryTalk Linx.

•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.

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 Programming Best Practices on page 71.

•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. You can use produced unicast connections that remote consumers consume.

•Outputs controlled by IOT instructions are not guaranteed to maintain a bumpless transition during a switchover. Due to this, it is recommended to avoid using IOT instructions within a redundancy system.

•The HMIBC instruction is not supported in a redundancy system.

•You can use one controller of the same family, and seven EtherNet/IP communication modules in each chassis of a redundant chassis pair.

•Cannot use Listen Only or Input Only connections for FLEX 5000 I/O and ControlLogix 1756 HART I/O from a redundant controller.

-There is no ability for another controller to listen or dual-own connections to FLEX 5000 I/O.

-This means no sharing of FLEX 5000 I/O or Highly Integrated HART between a the redundant controller pair and other controllers.

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Chapter 1 ControlLogix 5580 High Availability Systems

Notes:

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Chapter 2

Configure the Redundancy System

Topic	Page
Before You Begin	21
Download the Redundancy Firmware Bundle	22
Install the Firmware Bundle	22
Install the Redundancy Module Configuration Tool	22
Install the Redundancy System	23
Configure Redundant Firmware	24
Set the initial Primary and Secondary Chassis	25

Before You Begin

Complete these tasks before you configure the redundancy system:

IMPORTANT For best performance, place the redundancy module in the chassis as close as possible to the controller.

•Read and understand the safety and environmental considerations explained in the installation instructions publication for each component.

•Order a 1756-RMCx fiber-optic communication cable if you do not have one.

•If you choose to make your own fiber-optic cable for lengths that the 1756-RMCx catalog numbers do not support, refer to Fiber-optic Cable on page 15.

•Download and install the compatible versions of the Studio 5000 Logix Designer® application, RSLinx® Classic or FactoryTalk® Linx communication software, and ControlFLASH Plus™ software.

For information on how to download and install ControlFLASH Plus software, see the ControlFLASH Plus Quick Start Guide, publication CFP-QS001

IMPORTANT If RSLinx Classic software or FactoryTalk Linx is already on your system, make sure to shut it down before installing/upgrading software.

•Review the release notes for the firmware bundle that you are installing. Make sure that you have compatible hardware and the correct firmware revisions.

•Determine the IP address for each of your Ethernet/IP™ communication modules. Both Ethernet/IP communication modules of the redundant chassis pair will usually have the same IP address. See IP Address Swapping on page 29.

•System scan time will likely be different between a synchronized and unsynchronized system. See Crossloads, Synchronization, and Switchovers on page 61

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Chapter 2 Configure the Redundancy System

Download the Redundancy

Firmware Bundle

Install the Firmware Bundle

Install the Redundancy

Module Configuration Tool

You can download the appropriate redundancy firmware bundle from the Rockwell Automation Product Compatibility and Download Center (PCDC).

1.Go to https://compatibility.rockwellautomation.com/Pages/home.aspx.

2.Search for ‘1756-L8x Redundancy Bundle’.

3.Select and download the appropriate bundle revision.

The Redundancy Module Configuration Tool (RMCT) is included in the redundancy bundle download, and is not available for separate download.

Follow the steps in this section.

Create a firmware directory on your computer first, so you can unzip the files to this directory.

1.You must first shut down RSLinx Classic software.

2.Browse to the location of the redundancy firmware revision bundle.

3.Unzip the redundancy firmware bundle on your computer. After you unzip, you will have these files:

•Firmware: Vxx.0xx_kitx_5580CLXRED Bundle.dmk (where x is the firmware revision and kit number)

•Redundancy Module Configuration Tool

4.Unzip the Redundancy Module Configuration Tool on your computer.

The RMCT version that is compatible with your redundancy module firmware is included in the downloads for the redundancy bundle, and is not available as a separate download.

IMPORTANT You must uninstall any existing version of the Redundancy Module Configuration Tool (RMCT) before you install the RMCT, version 8.06.03 or later. If you do not uninstall the previous version, you can have difficulty if you try to uninstall version 8.06.03 or later at another time.

To install the RMCT:

1.Browse to the RMCT directory on your computer.

2.Double-click setup.exe.

3.On the RMCT Setup dialog, click Next.

4.When the installation is complete, click Finish.

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Install the Redundancy

System

Chapter 2 Configure the Redundancy System

If you need to install the redundancy system, determine the location of your controller, Ethernet/IP communication modules, and redundancy modules in both chassis of the system, matching partners slot for slot.

IMPORTANT Do not power on either chassis until you have installed all modules in both chassis.

1.Install the first chassis and power supply (or redundant power supplies):

•ControlLogix® Chassis Installation Instructions, publication 1756-IN621

•ControlLogix Power Supply Installation Instructions, publication 1756-IN619

•ControlLogix Redundant Power Supply Installation Instructions, publication 1756-IN620

2.Install and connect the 1756-RM2 redundancy modules in both chassis:

•ControlLogix Redundancy Modules Installation Instructions, publication 1756-IN087.

3.Install the first chassis Ethernet/IP communication modules:

•1756 EtherNet/IP Communication Modules Installation Instructions, publication 1756-IN050

4.Install one controller in the first chassis of the redundant pair:

•ControlLogix 5580 Controllers Installation Instructions, publication 1756-IN043

5.Install the second chassis and power supply (or redundant power supplies).

6.Install the second chassis Ethernet/IP communication modules.

7.Install one controller in the second chassis of the redundant pair.

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Chapter 2 Configure the Redundancy System

Configure Redundant

Firmware

Use ControlFLASH Plus software to upgrade the firmware of each module in each chassis. For information on how to download, install, and use ControlFLASH Plus software, see the ControlFLASH Plus Quick Start Guide, publication CFP-QS001.

IMPORTANT • Apply power ONLY to the chassis that contains modules on which you are upgrading firmware.

•Redundancy module firmware that is contained in the redundancy system firmware bundle is designed for use with the 1756-RM2 and 1756RM2XT redundancy modules.

•All modules in both chassis must use firmware as defined in the 1756-L8x Redundancy Bundle.

Upgrade the Firmware in the First Chassis

IMPORTANT Redundancy module firmware that is contained in the redundancy system firmware bundle is designed for use with the 1756-RM2 and 1756-RM2XT redundancy modules.

Complete these steps to upgrade the firmware in the first chassis.

1.Apply power to the chassis.

2.Set the keyswitch on the controller to PROG.

3.Wait for the modules to complete their start-up scroll messages. Check Module and status indicators. During this time, the redundancy module conducts internal operations to prepare for an update.

Create a firmware directory on your computer first, so you can unzip the files to this directory.

4.Launch ControlFLASH Plus software, and upgrade the Ethernet communication module that you going to use as the gateway to the other modules.

5.Upgrade the 1756-RM2 redundancy module.

6.Once the firmware upgrade is complete, verify that the redundancy module status displays PRIM, which indicates a successful upgrade.

7.Use ControlFLASH Plus software to upgrade the rest of the modules in the chassis.

IMPORTANT • Verify the firmware revision of each module to make sure it matches the revision in the 1756-L8x Redundancy Bundle.

•Power off the first chassis after you have verified a successful update of each module.

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Set the initial Primary and Secondary Chassis

Chapter 2 Configure the Redundancy System

Upgrade the Firmware in the Second Chassis

Complete these steps to update the firmware for the modules in the second chassis.

1.Apply power to the second chassis.

2.Set the keyswitch on the controller to PROG.

3.Complete steps 3…7 in section Upgrade the Firmware in the First Chassis beginning on page 24 for the modules in the second chassis.

IMPORTANT • verify the firmware revision of each module to make sure it matches the revision in the 1756-L8x Redundancy Bundle.

•Power off the second chassis after you have verified a successful update of each module.

Power on the chassis you want to set as the initial primary chassis first. After you have applied power, verify all module pairs are at compatible firmware revision levels.

IMPORTANT • Do not apply power to the chassis until you have read the instructions for designating the primary chassis. Applying power to the chassis in the correct order is crucial to designating the primary and secondary chassis.

•Make sure both Ethernet/IP communication modules are set appropriately. See Data Server Communication Recovery Time Reduction During a Switchover on page 18.

•It is not recommended to load an application image until the primary and secondary racks are synchronized.

•Before you set the initial primary chassis and qualify the system, it is recommended to have the latest firmware installed. See Configure Redundant Firmware on page 24.

Complete these steps to designate the primary and secondary chassis of a redundant pair.

1.Verify that power is removed from both chassis.

2.Apply power to the chassis you want to designate as the primary chassis and wait for the status indicators of the module to display PRIM.

3.Apply power to the chassis you want to designate as the secondary chassis.

4.Verify primary and secondary chassis designations by viewing the redundancy module status displays.

See Redundancy Module Status Indicators on page 138 for specific redundancy module display information.

IMPORTANT If both modules have power applied to them simultaneously, the module with the lowest IP address is designated as the primary chassis and displays PRIM on the four-character display of the module. In addition, the PRI status indicator on the primary redundancy module is green. The secondary chassis displays either DISQ or SYNC, depending on the state of the secondary chassis. In addition, the PRI status light on the secondary redundancy module is not illuminated.

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Chapter 2 Configure the Redundancy System

After Designation

When you first apply power to the primary and secondary chassis, compatibility checks are carried out between the redundant chassis. Then, because the default Auto-Synchronization parameter is set to Always, qualification begins.

While the qualification occurs, the module status display transitions from DISQ (disqualified) to QFNG (qualifying) to SYNC (synchronized). The qualification completes in 1…3 minutes and the module status display indicates the qualification status.

After you verify the system is synchronized, you can download the user application to the primary controller. It automatically crossloads to the secondary controller.

Use this table as a reference when interpreting the qualification status of the modules that are displayed on the module status display.

	Module Status Display	Interpretation
	QFNG	Qualification processes are in progress.
		SYNC displays after qualification processes are complete.
	SYNC	This indicates that chassis configuration and the firmware revision levels are
		compatible and that the secondary chassis is ready to assume control if there is a
		major fault in the primary chassis.
		If DISQ continues to display after about 3 minutes, check the following:
		• Incorrect chassis configuration. That is, incompatible hardware is used.
	DISQ…QFNG…DISQ	• Incompatible firmware revisions are used between the primary and secondary
		modules.
		• The partnered EtherNet/IP modules are not set to the same IP Configuration.
		• The Auto-Synchronization parameter within the Redundancy Module Configuration
		Tool is set to Never or Conditional (default setting).

Conversion from a Non-redundant to a Redundant System

To upgrade a standalone chassis to a redundant chassis pair:

1.Insert a redundancy module in a spare slot in the standalone chassis, and

2.Configure an identical chassis with compatible modules in the same slot as the standalone chassis (including the redundancy module).

A partnered chassis that is set as the secondary chassis stops functioning if it contains:

•non-redundancy-compliant modules

•modules not compatible with redundancy

•non-redundancy-compliant firmware

For more information, see Convert from a Non-redundant System on page 143.

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Chapter 2 Configure the Redundancy System

Qualification Status Via the RMCT

To view the details for a qualification attempt, access the Synchronization or Synchronization Status tabs of the RMCT. These tabs provide information about qualification attempts and redundant chassis compatibility.

For more information on how to use the RMCT, see Use the RMCT for Synchronization Attempts and Status on page 111.

RMCT Synchronization Status Tab

Synchronization Status Tab for Chassis Compatibility

You can also view events specific to qualification in the Event Log of the RMCT.

Event Log with Qualification Events

Reset the Redundancy Module

There are two ways to reset the module.

•Cycle power to the chassis.

•Remove the module from the chassis and reinsert the module.

IMPORTANT Do not choose to cycle power to the chassis if it causes you to lose control of your process.

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Chapter 2 Configure the Redundancy System

Remove or Replace the Redundancy Module

IMPORTANT If you remove the redundancy module, you will lose redundancy functionality.

To remove or replace the redundancy module, follow these steps.

1.To disengage the upper and lower module tabs, push them.

2.Slide the module out of the chassis.

3.Insert the replacement in the same slot and move the fiber cable(s) to the new module.

IMPORTANT If you want to resume system operation with an identical module, you must install the new module in the same slot.

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Chapter 3

Configure the EtherNet/IP Network

Requested Packet Interval (RPI)

Topic	Page
Requested Packet Interval (RPI)	29
IP Address Swapping	29
CIP Sync	33
Produce/Consume Connections	35
Configure EtherNet/IP Communication Modules in a Redundant System	37
Use a Redundancy System with Device Level Ring	38
Use a Redundancy System with Parallel Redundancy Protocol	38

The RPI for I/O connections in a redundant-enabled controller tree are configured the same way as a with a simplex controller. Adjusting the RPI rates of I/O connections impact the loading of the associated EtherNet/IP communications modules.

The RPI for I/O connections in a redundant-enabled controller tree are configured the same way as a with a simplex controller. Adjusting the RPI rates of I/O connections impact the loading of the associated EtherNet/IP communications modules.

This table describes CPU usage for EtherNet/IP™ communication modules.

	If the CPU utilization	Then
	percent is
	0…80%	No action is required.
		Important: This range is the optimal rate.
		• Take steps to reduce your CPU utilization. See the EtherNet/IP Network Configuration User
		Manual, publication ENET-UM001.
		• Adjust the requested packet interval (RPI) of your connection.
	Greater than 80%	• Reduce the number of devices that are connected to your module.
		• Add another Ethernet module to the redundant chassis pair (maximum of 7)
		Important: Your EtherNet/IP communication module can function at 100% CPU
		capacity, but at or near this rate, you run the risk of CPU saturation and
		performance degredation.

IP Address Swapping

IP address swapping is a feature available to EtherNet/IP communication modules in a redundancy system where a partnered set of EtherNet/IP communication modules swap IP addresses during a switchover.

IMPORTANT You must use IP address swapping to use remote I/O and produce/consume connections of an EtherNet/IP network.

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Chapter 3 Configure the EtherNet/IP Network

Determine Use of IP Address Swapping

Depending on your EtherNet/IP network configuration, you can choose to use IP address swapping between your partnered EtherNet/IP communication modules in the event of a switchover.

If you want to	Then
Minimize data server communication recovery time during switchover(1)	Do not use IP address swapping
Have your partnered EtherNet/IP communication modules on different subnets
Use Remote I/O or produce/consume	Use IP address swapping
Have your partnered EtherNet/IP communication modules on the same subnet.

(1) For more information, see Data Server Communication Recovery Time Reduction During a Switchover on page 18

If you are using different subnets, you are responsible for programming your system to use the address and subnet of the new primary chassis in the event of a switchover.

Do Not Use IP Address Swapping

If you do not use IP address swapping, assign unique values for the IP address on both EtherNet/IP communication modules in the partnered set:

IMPORTANT The IP address cannot be of the following format between the partner

EtherNet modules: aaa.bbb.ccc.ddd & aaa.bbb.ccc.(ddd+1)

Use IP Address Swapping

If you use IP address swapping, at minimum, the below parameters must be configured on both EtherNet/IP communication modules in the partnered set:

•IP address

•Subnet mask

Figure 1 shows a partnered set of EtherNet/IP communication modules during initial configuration.

Figure 1 - IP Addresses of EtherNet/IP Communication Modules During System Configuration

Assigned IP Address: 192.168.1.3

Primary chassis

CH2 CH1 OK

CH2 CH1 OK

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