LOGIX HOT BACKUP
BEGIN
SOLUTIONS
Reduce unplanned downtime with Logix
redundant control solutions
Downtime is
a certainty.
What’s the plan?
Lost production is inevitable, so planning for outages is critical.
Part of that planning process should include an understanding of control system
reliability. This has a different meaning in every industry, so going back to the
basics is necessary. Identifying the type of disruption and severity of the outcome
can help you evaluate risk mitigation options should a downtime incident occur.
A good place to start is with a risk assessment. Depending on your specific
manufacturing environment and application, the results of the assessment
can help determine suggested techniques to help keep your people and your
equipment safe.
One of those suggestions may be to build controller redundancy into your
operations. Before diving into the details, what are some of the considerations
in your specic industry and application?
What ’s the plan?
PG 2
The cost of doing nothing
PG 4
Redundant capability
PG 5
Controller redundancy options
PG 6
2
WITH SOME PROCESSES,
REDUNDANT CONTROLLERS
ARE TWICE AS NICE!
Some production environments are continuous
or irreversible and require high availability at
all costs. Disruption of the process could be
catastrophic from both a safety and profitability
perspective. If any failure or stoppage occurs
after production starts, the product is often
scrapped, and the process reinitiated to realize
a quality output. Think life sciences, food and
beverage, pulp and paper, oil and gas, mining,
cement, etc.
Other industries or applications simply can’t
afford to restart their production because it
can take days, weeks, even up to a month to get
back to full operation. A perfect example is the
metals industry. What if a large furnace in a steel
mill experiences a failure? It could take days to
reach a stable operating temperature again so
production can resume.
Although these examples are more aligned with
critical industries where reliability at the highest
levels is required, some applications need high
availability for other reasons, including customer
service. Think baggage handling.
In ALL these cases, what might be the cost of
not implementing redundant control?
What ’s the plan?
PG 2
The cost of doing nothing
PG 4
Redundant capability
PG 5
Controller redundancy options
PG 6
3
WHAT’S THE COST OF DOING NOTHING?
Wouldn’t it be great if you could predict anomalies in your operations so
you could identify and potentially eliminate downtime before it occurs?
Technology advancements in artificial intelligence and machine learning
might be a good strategy, but often require a data scientist to mine
and make sense of the data. In the end, there are several alternatives
to consider to help prevent stoppages, including system redundancy.
Weighing the costs and the risks of those options is part of the critical
decision-making process. One of those alternatives is the “do nothing”
scenario, but that can come at a high price:
Loss of product
As mentioned previously, any interruption of continuous processes can
result in loss of profit, uptime, and product. Machines sit idle, materials are
scrapped, and processes and people must recalibrate and start over.
Increased downtime
When your capital assets are out of commission, there’s more at stake
than lost production. Downtime leads to the non-utilization of resources,
not only for the equipment that’s experiencing the breakdown, but also for
the upstream and downstream equipment in your process workflow. This
translates to non-utilization of your human resources as well.
Increased TCO/decreased ROI
When human and capital resources are not in use due to a downtime incident,
tangible and intangible company resources continue to be consumed which
affects the bottom line. Total cost of ownership increases while your return
on investment decreases, and that’s not a good combination.
Avoid these scenarios by choosing an alternative that’s somewhere in
between the “do nothing” and the data scientist — controller redundancy
with Logix. With an investment in extra hardware and the accompanying
software, you can help reduce unplanned downtime caused by failures,
faults or system maintenance requirements.
What’s the plan?
PG 2
The cost of doing nothing
PG 4
Redundant capability
PG 5
Controller redundancy options
PG 6
4
Logix controllers
with redundant capability
Reliable control systems deliver consistent
operation of yourproduction oor. To increase
reliability, consider implementing redundant
control into your system.
Redundant capability isn’t new to the Logix family of
controllers. In fact, it’s been available in different form factors
for quite some time. Continued investment now makes this
functionality available in the latest additions to the Logix
product portfolios.
Whether you have a need for large or small control, you have
options with ControlLogix® and CompactLogix™ controllers.
And whether you need one-click activation or would
rather program the data sync yourself, Studio 5000 Logix
Designer® software provides the design environment for
configuring your redundant control.
What’s the plan?
PG 2
The cost of doing nothing
PG 4
Redundant capability
PG 5
Controller redundancy options
PG 6
5
5
Logix control redundancy details
DOWNLOADDOWNLOAD
DOWNLOADDOWNLOAD
DOWNLOADDOWNLOAD
CONTROLLOGIX REDUNDANCY HOT BACKUP
Controller support ControlLogix 5580 ControlLogix 5570
Required module 1756-RM2 1756-RM2 n/a
Network support EtherNet/IP
I/O support 1756, 5094, 1794, 1734, 1738, 1715 1756, 1794, 1734, 1738, 1715 1756, 1794, 5069
Software Studio 5000 Logix Designer v33
Data synchronization Automatic Automatic User congured
Switchover time >= 20ms >= 20ms >= 250ms
Program duplication for secondary controller Automatic Automatic User initiated
Online edits Automatically sent to both controllers Automatically sent to both controllers User initiated in both controllers
Network address swap for HMI Yes Yes, onEtherNet/IP No
Forced status equalization Yes Yes No
Output status during switchover Maintained Maintained Maintained
TM
EtherNet/IP and ControlNet
Studio 5000 Logix Designer
RSNetWorx
TM
(if using ControlNet)
TM
ControlLogix 5570/5580
CompactLogix 5370/5380
EtherNet/IP
ControlNet (ControlLogix only)
Studio 5000 Logix Designer
LogixHot BackupCodeGenerator
RSNetworx (if using ControNet)
High availability systems reference manual
What’s the plan?
PG 2
Firmware update in run mode Yes Yes Yes
User manual
The cost of doing nothing
PG 4
Redundant capability
PG 5
Controller redundancy options
PG 6
Contact local sales oce
(Reference Technical Note 68593)
6
ControlLogix 5580 controller quick look
Controller
catalog
1756-L8xE
1756-L8xE-NSE
1756-L8xEK
1756-L8xEXT
1756-L8xEP
1756-L8xES
Description Ethernet
Standard
controller
No stored
energy
Conformally
coated
Extreme
temperature
Process
controller
Safety
controller
■
■
■
■
■
■ ■ ■ ■ ■ ■
Network Support I/O Support Security Process
Use of
embedded
Ethernet port
▲ ▲
▲ ▲
▲ ▲
▲ ▲
▲ ▲
ControlNet /
DeviceNet /
DHRIO
Existing
I/O*
■
■
■
■
■
5069
I/O
▲
▲
▲
▲
▲
5094
I/O
■
■
■
■
■
CIP
security
62443-4-2
compliant
▲ ▲
▲ ▲
▲ ▲
▲ ▲
▲ ▲
● ● ●
Embedded
process
objects
●
●
●
●
■ ■
Phase
Manager™
software
■
■
■
■
■
Sequence Manager™
software
High
Availability
Default
Process Tasking
model
● ●
● ●
● ●
● ●
●
● ● ●
■ ■
Supports a
redundancy
conguration**
■
■
■
■
■ Supported in all congurations
▲ Supported in standard (but not redundant) conguration
● Not Supported
* ControlLogix® 5580 controllers congured for redundancy will support the same I/O as a ControlLogix® 5570 redundant controller; for example, 1769 I/O isn’t supported in a ControlLogix® 5570 redundant controller,
so it’s also not supported with ControlLogix® 5580 redundancy
** New functionality delivered through the Studio 5000 Logix Designer® application version 33 rmware and software; no new controller catalog number required to enable this feature
What’s the plan?
PG 2
The cost of doing nothing
PG 4
Redundant capability
PG 5
Controller redundancy options
PG 6
7
7
Whether you are in an industry where near 100% uptime with
BACK
full backup capabilities is required, or work in a different
industry where high availability is needed for other reasons, you
have options.
With scalable alternatives for I/O, memory, and cost, Logix
redundant controllers deliver high performance and high
availability for all industries and application needs.
LEARN MORE
rockwellautomation.com
ControlLogix
CompactLogix
Contact your local RA sales/distributor
Connect with us.
Allen-Bradley, ControlLogix, CompactLogix, expanding human possibility, FactoryTalk, Rockwell Automation, RSNetWorx, Studio 5000 Logix Designer are trademarks of Rockwell Automation, Inc.
ControlNet and EtherNet/IP are trademarks of ODVA, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Publication 1756-PP014C-EN-P - November 2020 | Supersedes Publication 1756-PP014B-EN-P - December 2012
Copyright © 2020 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
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