Page 1 User Manual ControlLogix Enhanced Redundancy System Catalog Numbers 1756-RM, 1756-RMXT, 1756-RM2, 1756-RM2XT...
Page 2 Identifies information that is critical for successful application and understanding of the product. Allen-Bradley, ControlFLASH, ControlLogix, FactoryTalk, PanelView, PhaseManager, Rockwell Software, Rockwell Automation, RSLinx, RSLogix, RSNetWorx, VersaView, RSView32, Logix5000, ControlLogix-XT, Integrated Architecture, Stratix 8000, PowerFlex, POINT I/O are trademarks of Rockwell Automation, Inc.
Page 3 ‘redundancy module.’ This manual includes SIL2 application information. Features of enhanced redundancy system using 1756-RM2/A module. Replace 1756-RM/B redundancy modules with 1756-RM2/A redundancy modules without initiating a switchover. Fiber channels will experience a delay during a switchover, but will remain synched.
Page 4 Table 1 - New and Updated Information Topic Page SFP error message. Added missing Module Status Display descriptions for the 1756-RM/A and 1756-RM/B modules. Replace 1756-RM/B redundancy modules with 1756-RM2/A redundancy modules without initiating a switchover. Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 5: Table Of Contents
Table of Contents Preface Additional Resources ..........13 Chapter 1 About Enhanced Redundancy Features of the ControlLogix Enhanced Redundancy System .
Page 6 Table of Contents Install the Software ......... . . 53 Add the EDS Files .
Page 7 Table of Contents Options for Setting the IP Addresses of EtherNet/IP Communication Modules........86 Half/Full Duplex Settings.
Page 8 Table of Contents System Event History ..........136 Edit a User Comment for a System Event .
Page 9 Table of Contents Load a Project..........182 Online Edits .
Page 10 1756-RM2/A and 1756-RM2XT Status Indicators... . . 227 1756-RM/A and 1756-RM/B Status Indicators ....230 Redundancy Module Fault Codes and Display Messages .
Page 11 Table of Contents Appendix G Enhanced Redundancy Revision Changes to This Manual......... 283 History Index Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 12 Table of Contents Notes: Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 13: Additional Resources
Preface This publication provides this information specific to enhanced redundancy systems: • Design and planning considerations • Installation procedures • Configuration procedures • Maintenance and troubleshooting methods This publication is designed for use by anyone responsible for planning and implementing a ControlLogix® enhanced redundancy system: •...
Page 14 RFID readers, or other standard Ethernet devices. You can view or download publications at http:// www.rockwellautomation.com/literature/. To order paper copies of technical documentation, contact your local Allen-Bradley® distributor or Rockwell Automation sales representative. Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 15 Chapter About Enhanced Redundancy Systems Topic Page Features of the ControlLogix Enhanced Redundancy System Enhanced Redundancy System Components Enhanced Redundancy System Operations Restrictions The ControlLogix Enhanced Redundancy System is a system that provides greater availability because it uses a redundant chassis pair to maintain process operation when events, such as a fault on a controller, occur that stop process operation on nonredundant systems.
Page 16: Features Of The Controllogix Enhanced Redundancy System
• Redundancy module speeds of up to 1000 Mbps when using a 1756- RM2/A module with another 1756-RM2/A module. Redundancy module speeds up to 100 Mbps when using a 1756-RM/A with another 1756-RM/A module, and a 1756-RM/B module with another 1756-RM/ B module.
Page 17: Enhanced Redundancy System Components
About Enhanced Redundancy Systems Chapter 1 Features Not Supported • Any motion feature • Any SIL3 functional safety feature within the redundancy controllers • Firmware Supervisor • Event Tasks • Firmware revision 19.052 for 1756-L7x controller 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.
Page 18: I/O Modules In Enhanced Redundancy Systems
Chapter 1 About Enhanced Redundancy Systems I/O Modules in Enhanced Redundancy Systems In an enhanced redundancy system, you can use only I/O modules in a remote chassis. You cannot use I/O modules in the redundant chassis pair. This table describes differences in network use for I/O in enhanced redundancy systems.
Page 19: Enhanced Redundancy System Operations
About Enhanced Redundancy Systems Chapter 1 Enhanced Redundancy 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 System Operations secondary chassis. The redundancy modules in both the primary and secondary chassis monitor events that occur in each of the redundant chassis.
Page 20: Switchovers
For more information on these considerations, see Chapter Program the Redundant Controller on page 141. For instructions about how to replace 1756-RM/B redundancy modules with IMPORTANT 1756-RM2/A redundancy modules without initiating a switchover, see Replace 1756-RM/A or 1756-RM/B Redundancy Modules with 1756-RM2/A Redundancy Modules on page 264.
Page 21 About Enhanced Redundancy Systems Chapter 1 HMI Blind Time Reduction on Ethernet During a Switchover HMI Blind Time is the time during a switchover from primary to secondary, when tag data from the controller is unavailable for reading or writing. HMI Blind Time is associated with visualizing process operations from an HMI;...
Page 22: Restrictions
• The 1756-RM2/A or 1756-RM2XT modules can be used only with other 1756-RM2/A or 1756-RM2XT modules. You cannot mix 1756-RM2/A and 1756-RM2XT modules with 1756-RM/A, 1756-RM/B, or 1756- RMXT modules. • Please note that firmware revision 19.052 applies to 1756-L6x controllers only and revision 19.053 applies to 1756-L7x controllers only.
Page 23 Chapter Design an Enhanced Redundancy System Topic Page Components of an Enhanced Redundancy System Redundant Chassis Controllers in Redundant Chassis Redundancy Modules in Redundant Chassis Communication Modules in Redundant Chassis Power Supplies and Redundant Power Supplies in Enhanced Redundancy Systems ControlNet Networks with Redundant Systems Other Communication Networks Other Communication Networks...
Page 24: Components Of An Enhanced Redundancy System
1756-RM2XT ControlLogix-XT™ redundancy module This component is available with enhanced redundancy systems, revision 16.057, 16.081, 19.052 or later when using 1756-L6x controllers, and 19.053 or later when using 1756-L7x controllers. 1756-RM ControlLogix redundancy module 1756-RMXT ControlLogix-XT redundancy module Chassis 1756-A4...
Page 25 Design an Enhanced Redundancy System Chapter 2 Table 4 - Components Available for Use in a Redundant Chassis Pair Product Type Cat. No. Description Page Controllers 1756-L61, 1756- ControlLogix controllers L62, 1756-L63, 1756-L64 1756-L63XT ControlLogix-XT controller 1756-L65 ControlLogix controller This component is available with enhanced redundancy systems, revision 19.052 or later.
Page 26 Chapter 2 Design an Enhanced Redundancy System This graphic shows an example ControlLogix enhanced redundancy system, revision 19.053 or later, that uses EtherNet/IP networks. Figure 1 - Example ControlLogix Enhanced Redundancy System, Revision 19.053 or later, Using an EtherNet/IP Network Workstation EtherNet/IP Switch...
Page 27 Design an Enhanced Redundancy System Chapter 2 This graphic shows an example ControlLogix enhanced redundancy system, revision 19.053 or later, that uses ControlNet networks. Figure 2 - Example ControlLogix Enhanced Redundancy System, Revision 19.053 or later, Using a ControlNet Network Workstation EtherNet/IP Switch...
Page 28: Redundant Chassis
Chapter 2 Design an Enhanced Redundancy System Redundant Chassis You can use any ControlLogix or ControlLogix-XT chassis in a redundant chassis pair as long as the two chassis used are the same size. For example, if the primary chassis in your redundant chassis pair uses a 1756-A4 chassis, the secondary chassis must use a 1756-A4 chassis.
Page 29: Controllers In Redundant Chassis
Design an Enhanced Redundancy System Chapter 2 Controllers in Redundant Chassis Remember these points when placing controllers in the redundant chassis pair: • Controllers are typically included, but not required, in enhanced redundancy systems. • The differences between controller types are described in this table. Table 5 - Controller Features Feature 1756-L7x Controllers...
Page 30 Chapter 2 Design an Enhanced Redundancy System • Each controller must have enough I/O memory to store twice the amount of I/O memory used. To check the I/O memory used and available, access the Memory tab of the Controller Properties dialog box in RSLogix 5000 software.
Page 31: Redundancy Modules In Redundant Chassis
Design an Enhanced Redundancy System Chapter 2 Plan for Controller Connections Consider these conditions when planning controller connection use: • 1756-L6x controllers provide 250 total connections. • 1756-L7x 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.
Page 32: Communication Modules In Redundant Chassis
Chapter 2 Design an Enhanced Redundancy System 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 enhanced redundancy systems. Enhanced communication modules contain a ‘2’ in their catalog number.
Page 33 Design an Enhanced Redundancy System Chapter 2 Plan for Communication Module Connections A CIP connection is a point-to-point communication mechanism used to transfer data between a producer and a consumer. These are examples of CIP connections: • Logix5000 controller message transfer to Logix5000 controller •...
Page 34: Redundancy Systems
Chapter 2 Design an Enhanced Redundancy System Power Supplies and Redundant Power Supplies in Enhanced Redundancy Systems You can use any of the standard or redundant power supplies listed in Components Available for Use in a Redundant Chassis Pair on page 24 in an enhanced redundancy system.
Page 35: Ethernet/Ip Networks With Redundant Systems
Design an Enhanced Redundancy System Chapter 2 EtherNet/IP Networks with The use of EtherNet/IP networks in an enhanced redundancy system is primarily dependent on your system revision. Redundant Systems A remote chassis can be accessed over an EtherNet/IP network using any IMPORTANT EtherNet/IP module that works in a nonredundant chassis with no additional firmware requirement with the following exception.
Page 36: Ip Address Swapping
Chapter 2 Design an Enhanced Redundancy System IP Address Swapping EtherNet/IP communication modules can use IP address swapping to swap IP addresses during a switchover. You must use this feature to use Ethernet I/O connections. For more information on IP address swapping, see Chapter Configure the ControlNet Network on page...
Page 37 Design an Enhanced Redundancy System Chapter 2 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 in addition to the EtherNet/IP and ControlNet communication modules.
Page 38: Controlnet Networks With Redundant Systems
Chapter 2 Design an Enhanced Redundancy System ControlNet Networks with ControlNet networks are used to connect redundant control chassis to remote I/O and to other devices in the system. Redundant Systems A remote chassis can be accessed over a ControlNet network using any IMPORTANT ControlNet module that works in a nonredundant chassis with no additional firmware requirement.
Page 39 Design an Enhanced Redundancy System Chapter 2 Assign Lowest Node Numbers to Remote ControlNet Modules Do not assign the lowest ControlNet node addresses to ControlNet modules in the redundant chassis pair. If you assign the lowest ControlNet node addresses to ControlNet modules in the redundant chassis pair, you can experience these system behaviors: •...
Page 40 Chapter 2 Design an Enhanced Redundancy System Reserve Consecutive Node Addresses for Partner Modules Where ControlNet modules are used as partners in redundant chassis, plan consecutive node numbers for those partnered modules. Plan for consecutive node addresses because the redundant system automatically assigns the consecutive node address to the secondary ControlNet module.
Page 41: Redundant Controlnet Media
Design an Enhanced Redundancy System Chapter 2 Redundant ControlNet Media The use of redundant ControlNet media helps to prevent a loss of communication if a trunkline or tap is severed or disconnected. A system that uses redundant ControlNet media uses these components: •...
Page 42: Other Communication Networks
Chapter 2 Design an Enhanced Redundancy System Other Communication You can use only EtherNet/IP and ControlNet networks, and corresponding modules, in enhanced redundancy systems. Networks Do not use the redundant chassis to bridge between networks. Bridging IMPORTANT through the redundant chassis to the same or different networks, or routing messages through redundant chassis is not supported.
Page 43 Design an Enhanced Redundancy System Chapter 2 You can bridge these networks via a remote chassis: • ControlNet • DeviceNet • EtherNet/IP • Universal Remote I/O • Data Highway Plus This table indicates what system components can be used with each network connected to a redundant system.
Page 44: I/O Placement
Chapter 2 Design an Enhanced Redundancy System I/O Placement In an enhanced redundancy system, you can place I/O modules in these locations: • Same ControlNet network as redundant controllers and communication modules • Same EtherNet/IP network as redundant controllers and communication modules •...
Page 45 Design an Enhanced Redundancy System Chapter 2 Figure 10 - Example of I/O Placement Options Workstation EtherNet/IP EtherNet/IP Switch Primary Chassis Secondary Chassis CH2 CH1 OK CH2 CH1 OK EtherNet/IP Bridging Chassis 1734 POINT I/O 1715 Redundant I/O ControlNet DeviceNet Device 1771 Chassis with Control Tower 1771-ASB...
Page 46: Using Hmi
Chapter 2 Design an Enhanced Redundancy System Using HMI Depending on the network used to connect the redundant system to HMIs, plan for certain placement and configuration requirements. You can connect an HMI to a primary chassis over either of these networks: •...
Page 47: Hmi Connected Via A Controlnet Network
Design an Enhanced Redundancy System Chapter 2 HMI Connected via a ControlNet Network This table describes redundant system considerations specific to the HMI being used on the ControlNet network. Type of HMI Used Considerations • PanelView Standard terminal • If your HMI communicates via unscheduled communication, use four terminals per controller.
Page 48 Chapter 2 Design an Enhanced Redundancy System Connection from HMI Over a ControlNet Network shows an example of connecting an HMI to a primary controller over a ControlNet network. Figure 11 - Connection from HMI Over a ControlNet Network ControlNet Redundant Chassis Pair CH2 CH1 OK CH2 CH1 OK...
Page 49: Firmware Requirements
Design an Enhanced Redundancy System Chapter 2 Firmware Requirements If you are using an enhanced redundancy system, use only enhanced redundancy system firmware. These are the enhanced redundancy system firmware-revision bundles: • 16.054Enh • 16.080Enh • 16.081Enh • 16.081_kit1 • 19.052Enh •...
Page 50: Optional Software
Chapter 2 Design an Enhanced Redundancy System Optional Software Software in addition to that listed as required software can be needed depending on your enhanced redundancy system program, configuration, and components. Optional software you might need is listed in this table. If using Then use this software ControlNet network...
Page 51: Before You Begin
Chapter Install the Enhanced Redundancy System Topic Page Before You Begin Install an Enhanced Redundancy System Step 1: Install the Software Step 2: Install the Hardware Step 3: Connect the Redundancy Modules via a Fiber-optic Cable Step 4: Update Redundant Chassis Firmware Step 5: Designate the Primary and Secondary Chassis Before You Begin Complete these tasks before you install the enhanced redundancy system:...
Page 52 Chapter 3 Install the Enhanced Redundancy System 2. To begin the hardware installation, determine the location of your modules in the system’s chassis. Plug in the communication modules, controller and redundancy modules into the chassis, matching partners slot for slot. See Step 2: Install the Hardware on page Install the following: •...
Page 53: Install An Enhanced Redundancy System
Install the Enhanced Redundancy System Chapter 3 Install an Enhanced The following steps detail the installation process for an enhanced redundancy system. They also explain how to install the redundant modules. These steps Redundancy System include the following. 1. Installing the software 2.
Page 54: Add The Eds Files
Chapter 3 Install the Enhanced Redundancy System When using the 1756-RM2/A or 1756-RM2XT module, you must use version IMPORTANT 8.01.05 or later of the RMCT. When the redundancy module firmware is upgraded, the RMCT is updated. The RMCT automatically uses the version that is compatible with the redundancy module firmware revision installed.
Page 55: Install The Chassis And Power Supply
Install the Enhanced Redundancy System Chapter 3 The redundancy module prevents certain redundancy operations, such as Qualification, if incompatible modules reside in the redundant-control chassis pair. For best performance, place the redundancy module in the chassis as close as IMPORTANT possible to the controller.
Page 56: Install The Communication Modules
Chapter 3 Install the Enhanced Redundancy System Install the Communication Modules Use the installation information provided with the communication modules to install them in an enhanced redundancy system. Table 10 - Communication Module Installation Product Type Cat. No. Publication ControlNet 1756-CN2/B communication ControlNet Modules Installation Instructions,...
Page 57: Install The Redundancy Module
• Verify that your enhanced redundancy firmware revision is compatible with your planned redundant chassis modules • The 1756-RM/B module offers a higher level of performance than a 1756- RM/A module. Both modules can coexist in a redundant system, but the highest system performance is achieved when the 1756-RM/B modules are used together when used in conjunction with a 1756-L7x controller.
Page 58: Environment And Enclosure
Chapter 3 Install the Enhanced Redundancy System Environment and Enclosure ATTENTION: This equipment is intended for use in a Pollution Degree 2 industrial environment, in overvoltage Category II applications (as defined in IEC 60664-1), at altitudes up to 2000 m (6562 ft) without derating. This equipment is not intended for use in residential environments and may not provide adequate protection to radio communication services in such environments.
Page 59: Safety-Related Programmable Electronic Systems
Install the Enhanced Redundancy System Chapter 3 ATTENTION: This equipment is not resistant to sunlight or other sources of UV radiation. WARNING: • This equipment must be installed in an enclosure providing at least IP54 protection when applied in Zone 2 environments. •...
Page 60: North American Hazardous Location Approval
Chapter 3 Install the Enhanced Redundancy System North American Hazardous Location Approval The following information applies when operating this equipment in hazardous Informations sur l'utilisation de cet équipement en environnements locations. dangereux. Les produits marqués "CL I, DIV 2, GP A, B, C, D" ne conviennent qu'à Products marked "CL I, DIV 2, GP A, B, C, D"...
Page 61 Install the Enhanced Redundancy System Chapter 3 A redundant system is comprised of two ControlLogix redundancy modules working together that supervise the operating states and state transitions that establish the basic framework for redundancy operations. The redundant pairs provide a bridge between chassis pairs that let other modules exchange control data and synchronize their operations.
Page 62 Chapter 3 Install the Enhanced Redundancy System Figure 13 - 1756-RM/A or RM/B and 1756-RMXT Modules 1756-RM/A or 1756-RM/B Module 1756-RMXT Module Top View Top View Front View Front View Status Indicators Status Indicators Redundancy Module PRI COM OK Side View...
Page 63: Install The Second Chassis
Install the Enhanced Redundancy System Chapter 3 Install the Second Chassis Once the first chassis and its components are installed, you can install the second chassis of the redundant chassis pair. Complete these tasks as described in the Install the First Chassis and its Components section to install the second chassis: •...
Page 64 Chapter 3 Install the Enhanced Redundancy System The cable connection is made at the bottom of the module in a downward orientation. There is enough space between the transmit and receive connectors so you can use the LC connector coupler. Using this coupler keeps the fiber-optic cable from bending so you can connect and disconnect the cable without removing the module from the chassis.
Page 65: Connect The Fiber-Optic Communication Cable To Redundant
Install the Enhanced Redundancy System Chapter 3 Connect the Fiber-optic Communication Cable to Redundant Channels Follow this procedure to install the communication cable to redundant channels for the 1756-RM2/A module. The redundancy module communication cable contains optical fibers. Avoid IMPORTANT making sharp bends in the cable.
Page 66: Single Channels
Chapter 3 Install the Enhanced Redundancy System Connect the Fiber-optic Communication Cable to Single Channels Follow this procedure to install the communication cable. The redundancy module communication cable contains optical fibers. Avoid IMPORTANT making sharp bends in the cable. Install the cable in a location where it will not be cut, run over, abraded, or otherwise damaged.
Page 67: Fiber-Optic Cable
Fiber-optic Cable If you choose to make your own fiber-optic cables, consider the following: • Fiber-optic Communication Cable Specifications Attribute 1756-RM2/A 1756-RM2XT 1756-RM/A or 1756-RM/B 1756-RMXT Temperature, 0…60 °C (32…140 °F) -25…70 °C (-13…158 °F) 0…60 °C (32…140 °F) -25…70 °C (-13…158 °F)
Page 68: Upgrade The Firmware In The First Chassis
Install the Enhanced Redundancy System Redundancy module firmware contained in the enhanced redundancy system IMPORTANT firmware bundle is designed for use with the 1756-RM, 1756-RM2/A, 1756- RMXT, and 1756-RM2XT redundancy modules. Upgrade the Firmware in the First Chassis Complete these steps to upgrade the firmware in the first chassis.
Page 69 3. Wait for the redundancy module to complete its start-up scroll messages. Check Module and status indicators. Wait 45 seconds before you begin updating the 1756-RM firmware. During this time, the redundancy module conducts internal operations to prepare for an update.
Page 70 Chapter 3 Install the Enhanced Redundancy System 5. Select the module’s catalog number (upgrade the redundancy module first) and click Next. The 1756-RM2/A module uses different firmware than the 1756-RM and 1756- IMPORTANT RMXT modules. 1756-RM/B 1756-RM2/A 6. Expand the network driver to locate the redundancy module or module you are upgrading.
Page 71: Upgrade The Firmware In The Second Chassis
Install the Enhanced Redundancy System Chapter 3 This can take a few minutes. The system can look like it is not doing anything, IMPORTANT but it is. When the update is complete, the Update Status dialog box appears and indicates that the update has successfully completed. 11.
Page 72 Chapter 3 Install the Enhanced Redundancy System 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 module’s status indicators to display PRIM.
Page 73: After Designation
Install the Enhanced Redundancy System Chapter 3 After Designation When you first apply power to the designated primary and secondary chassis, compatibility checks are carried-out between the redundant chassis. Then, because the default Auto-Synchronization parameter is set at Always, qualification begins. While the qualification occurs, the module status display transitions from DISQ (disqualified) to QFNG (qualifying) to SYNC (synchronized).
Page 74: Qualification Status Via The Rmct
Chapter 3 Install the Enhanced Redundancy System Qualification Status via the RMCT To view the 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 about using the RMCT, see Chapter Configure the Redundancy Modules on page...
Page 75: Reset The Redundancy Module
Install the Enhanced Redundancy System Chapter 3 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 Only choose to cycle power to the chassis if you will not lose control of your IMPORTANT process.
Page 76 Chapter 3 Install the Enhanced Redundancy System Notes: Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 77: Configure The Ethernet/Ip Network
Chapter Configure the EtherNet/IP Network Topic Page Requested Packet Interval Use IP Address Swapping Use CIP Sync Use Produce/Consume Connections Configure EtherNet/IP Communication Modules in a Redundant System Use An Enhanced Redundancy System in a Device-level Ring Topology Requested Packet Interval When using revisions earlier than 20.054, the RPI for I/O connections in a redundancy-enabled controller tree must be less than or equal to 375 ms.
Page 78 Chapter 4 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 your partnered EtherNet/IP communication modules are on Then Same subnet use IP address swapping...
Page 79 Configure the EtherNet/IP Network Chapter 4 When an enhanced redundancy system begins operating, the primary EtherNet/IP communication module uses the IP address assigned during initial configuration. The secondary EtherNet/IP communication module automatically changes its IP address to the next highest value. When a switchover occurs, the EtherNet/IP communication modules swap IP addresses.
Page 80: Static Versus Dynamic Ip Addresses
Chapter 4 Configure the EtherNet/IP Network Static versus Dynamic IP Addresses We recommend that you use static IP addresses on EtherNet/IP communication modules in enhanced redundancy system. ATTENTION: If you use dynamic IP addresses and a power outage, or other network failure occurs, modules using dynamic IP addresses can be assigned new addresses when the failure is resolved.
Page 81: Use Cip Sync
Configure the EtherNet/IP Network Chapter 4 Use CIP Sync Beginning with enhanced redundancy system revision 19.052 or later, you can use CIP Sync technology. CIP Sync technology provides a mechanism to synchronize clocks between controllers, I/O devices, and other automation products in your architecture with minimal user intervention.
Page 82 Chapter 4 Configure the EtherNet/IP Network • If the primary controller is the Grandmaster, the enhanced redundancy system automatically manages the CIP Sync clock attributes so that the controller in the primary chassis is always set to be the Grandmaster instead of the secondary controller.
Page 83 Configure the EtherNet/IP Network Chapter 4 This figure shows an example enhanced redundancy system, revision 19.052 or later, using CIP Sync technology. Use of ControlNet is not required when using CIP Sync technology in an enhanced redundancy system. It is included in this figure for example purposes. Figure 20 - Enhanced Redundancy System, Revision 19.052 or later, Using CIP Sync Technology Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 84: Use Produce/Consume Connections
Chapter 4 Configure the EtherNet/IP Network Use Produce/Consume Beginning with enhanced redundancy system, revision 19.053 or later, you can use produce/consume connections over an EtherNet/IP network. Controllers Connections let you produce (broadcast) and consume (receive) system-shared tags. When using 1756-L7x controllers in your system, you must use revision 19.053 or later.
Page 85: Configure Ethernet/Ip Communication Modules In A Redundant System
Configure the EtherNet/IP Network Chapter 4 If controllers in the redundant chassis pair produce tags over an EtherNet/IP IMPORTANT network that controllers in remote chassis consume, the connection from the remote controller to the redundant controller can briefly drop during a switchover.
Page 86: Options For Setting The Ip Addresses Of Ethernet/Ip
Chapter 4 Configure the EtherNet/IP Network Options for Setting the IP Addresses of EtherNet/IP Communication Modules By default, ControlLogix EtherNet/IP communication modules ship with the IP address set to 999 and with Bootstrap Protocol (BOOTP)/Dynamic Host Configuration Protocol (DHCP)-enabled. Use one of these tools to set the IP addresses for your EtherNet/IP communication modules: •...
Page 87: Use An Enhanced Redundancy System In A Device-Level Ring Topology
Configure the EtherNet/IP Network Chapter 4 Use An Enhanced A DLR network is a single-fault tolerant ring network intended for the interconnection of automation devices. This topology is implemented at the Redundancy System in a device level because the use of EtherNet/IP embedded switch technology embeds Device-level Ring Topology switches into the end devices themselves.
Page 88 Chapter 4 Configure the EtherNet/IP Network 2. Back-up Supervisor Node - An optional node that behaves like a ring node unless the active supervisor node cannot execute required tasks. At that point, the back-up node becomes the active supervisor node. •...
Page 89 Configure the EtherNet/IP Network Chapter 4 During normal operation, one of the active supervisor node’s network ports is blocked for DLR protocol frames. However, the active supervisor node continues to send beacon frames out of both network ports to monitor network health.
Page 90 Chapter 4 Configure the EtherNet/IP Network This graphic shows an example of an operating DLR network that includes an enhanced redundancy system. Figure 24 - Enhanced Redundancy System in a DLR Network FactoryTalk Application Cisco Switch Stratix 8000™ Switches Redundant Chassis Pair HMI Connected via 1783-ETAP Taps 1715 Redundant I/O System...
Page 91 Configure the EtherNet/IP Network Chapter 4 Complete these steps to construct and configure the example DLR network. 1. Install and connect devices on the DLR network but leave at least one connection open. When you initially install and connect devices on the DLR network, IMPORTANT leave at least one connection open, that is, temporarily omit the physical connection between two nodes on the DLR network.
Page 92 Chapter 4 Configure the EtherNet/IP Network 2. Configure and enable one active supervisor and any back-up nodes on the network. Use either of these tools to configure and enable supervisor nodes on a DLR network: • RSLogix 5000 programming software •...
Page 93: Configure The Controlnet Network
Chapter Configure the ControlNet Network Topic Page Produce/Consume Connections Network Update Time Use a Scheduled or Unscheduled Network Schedule a New Network Update an Existing Scheduled Network Check the Network Keeper States Produce/Consume You can use produce/consume connections over a ControlNet network. Controllers let you produce (broadcast) and consume (receive) system-shared Connections tags.
Page 94 Chapter 5 Configure the ControlNet Network Keep these points in mind when you use produced and consumed connections over a ControlNet network in an enhanced redundancy system: • During a switchover, the connection for tags that are consumed from a redundant controller can drop briefly.
Page 95: Network Update Time
Configure the ControlNet Network Chapter 5 Network Update Time The network update time (NUT) that you specify for your redundant system impacts your system performance and your switchover response time. Typical NUTs used with redundant systems range from 5…10 ms. NUTs with Multiple ControlNet Networks You can choose to use multiple ControlNet networks with your enhanced redundancy system.
Page 96 Chapter 5 Configure the ControlNet Network Use this table to determine the compatible NUTs for your system. Table 15 - Compatible NUT Values for Multiple ControlNet Networks If the smallest NUT of a Then the largest NUT of any other network must be less network is (ms) than or equal to (ms) 37...90...
Page 97: Use A Scheduled Or Unscheduled Network
Configure the ControlNet Network Chapter 5 Use a Scheduled or It is up to the user to decided between using a scheduled or unscheduled network. Unscheduled Network Use a Scheduled Network Schedule or reschedule your ControlNet network when you are executing these tasks: •...
Page 98: Add Remote Controlnet Modules While Online
Chapter 5 Configure the ControlNet Network Add Remote ControlNet Modules While Online If you are adding a remote I/O chassis comprised of a ControlLogix ControlNet module and ControlLogix I/O while your redundant system is running (online), make these considerations: • Do not use Rack Optimized communication formats. The ControlNet module and I/O must be configured for direct connections.
Page 99 Configure the ControlNet Network Chapter 5 8. In the Network Parameters tab, enter the parameters that are appropriate for your system. Parameter Specify Network Update Time (ms) The minimum repetitive interval when data is sent over the ControlNet network. Max Scheduled Address The highest node number that uses scheduled communication on the network.
Page 100: Update An Existing Scheduled Network
Chapter 5 Configure the ControlNet Network Update an Existing If you are adding the redundant chassis to an existing ControlLogix system that uses a ControlNet network, complete these steps to update the existing Scheduled Network ControlNet network. 1. Turn on the power to each chassis. 2.
Page 101: Check The Network Keeper States
Configure the ControlNet Network Chapter 5 Check the Network Keeper After you schedule your ControlNet network, check the states of keeper-capable nodes. Checking the status of keeper-capable nodes is important because if a States major network disruption occurs, the keepers provide network configuration parameters required to recover.
Page 102: Save The Project For Each Primary Controller
Chapter 5 Configure the ControlNet Network 4. Verify that all of the nodes on the network have the same keeper signature. Keeper signatures are all the same. If the keeper signatures of partnered ControlNet modules are different, your redundant chassis may not synchronize. If the keeper signatures of your partnered ControlNet modules are different, update the keepers of the redundant ControlNet modules.
Page 103 Configure the ControlNet Network Chapter 5 To replace a ControlNet module that has been configured and scheduled on the ControlNet network, remove the existing module and insert a 1756-CN2/B, 1756-CN2R/B, or 1756-CN2RXT module. The module you are inserting must be unconfigured or have a keeper signature of all zeros. To clear the keeper signature of a 1756-CN2, 1756-CN2R, or 1756-CN2RXT module, complete these steps.
Page 104 Chapter 5 Configure the ControlNet Network Notes: Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 105: Configure The Redundancy Modules
Chapter Configure the Redundancy Modules Topic Page About the Redundancy Module Configuration Tool (RMCT) Determine if Further Configuration is Required Use the RMCT Module Info Tab Configuration Tab Synchronization Tab Synchronization Status Tab Event Log Tab System Update Tab System Event History Using Dual Fiber Ports with the 1756-RM2/A Redundancy Module About the Redundancy The Redundancy Module Configuration Tool (RMCT) is used to configure the...
Page 106: Determine If Further Configuration Is Required
Chapter 6 Configure the Redundancy Modules The chassis platform configuration identifies the common operating platform of the modules in the redundant chassis and applies to all redundancy modules. It may be one of the following values depending on the redundancy release installed in the system and the type of communication modules running in the redundant chassis.
Page 107: Use The Rmct
Configure the Redundancy Modules Chapter 6 Use the RMCT To access and begin using the RMCT, launch RSLinx Classic software and browse to your redundancy module. Right-click the redundancy module and choose Module Configuration. Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 108 Chapter 6 Configure the Redundancy Modules When you access the RMCT, the dialog box always indicates the status of the redundancy chassis in the bottom-left corner. Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 109: Identify The Rmct Version
Configure the Redundancy Modules Chapter 6 Identify the RMCT Version You must use a version of the RMCT that is compatible with your redundancy module firmware. Beginning with version 20.054, the redundancy module firmware reports back to the Redundancy Module Configuration Tool (RMCT) as to which version of the RMCT is compatible.
Page 110: Update The Rmct Version
Chapter 6 Configure the Redundancy Modules The Module Configuration dialog box opens. 4. Right-click the title bar and choose About. The About dialog box opens and indicates the RMCT version. Update the RMCT Version The RMCT version that is compatible with your redundancy module firmware is packaged with the redundancy system firmware bundle.
Page 111: Module Info Tab
The Module Info tab of the RMCT provides a general overview of the redundancy module’s identification and status information. This status information is updated approximately once every two seconds. NOTE: Not all indicators are shown for 1756-RM/A and 1756-RM/B modules. Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 112 Chapter 6 Configure the Redundancy Modules These parameters are indicated in the Module Info tab. Table 17 - Module Info Tab - Parameters Indicated Parameter Description Vendor Name of the redundancy module’ s vendor. Product Type General product type of the redundancy module. Product Code CIP product code for the redundancy module.
Page 113: Configuration Tab
Configure the Redundancy Modules Chapter 6 Configuration Tab Use the Configuration tab to set redundancy options and the module’s internal clock. After you modify a parameter, the Apply Workstation Time button becomes active. Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 114: Auto-Synchronization
Chapter 6 Configure the Redundancy Modules Auto-Synchronization The first parameter in the Configuration tab is the Auto-Synchronization parameter. The value you set this parameter to determines a significant part of your redundant system behavior. Verify that your Auto-Synchronization parameter is at the proper value before you make any changes to your redundant system.
Page 115: Chassis Id
Configure the Redundancy Modules Chapter 6 Chassis ID The chassis ID parameter is used to assign a generic label to the chassis that house the redundancy modules. The available chassis labels are Chassis A and Chassis B. If you change the chassis label in the RMCT of the primary redundancy module, the secondary module and chassis are automatically assigned the other chassis label.
Page 116: Synchronization Tab
Chapter 6 Configure the Redundancy Modules Synchronization Tab The Synchronization Tab provides commands for these options: • Changing the synchronization state of the system (synchronize or disqualify) • Initiating a switchover • Forcing the disqualified secondary to become the primary The commands available are described in the Commands in the Synchronization section on...
Page 117: Commands In The Synchronization Tab
Configure the Redundancy Modules Chapter 6 Commands in the Synchronization Tab These sections explain each redundancy command and the system conditions that are required for the command to be available. Command Description Synchronize Secondary This command forces the primary redundancy module to attempt synchronization with its partner. This command is available in specific conditions: •...
Page 118: Recent Synchronization Attempts Log
Chapter 6 Configure the Redundancy Modules Recent Synchronization Attempts Log This table describes the possible result and causes of synchronization states. Table 18 - Recent Synchronization Attempts Log - Result Interpretations Result Result Interpretation Undefined The result of the synchronization is unknown. No attempt since last powerup Synchronization has not been attempted since power was applied to the module.
Page 119: Synchronization Status Tab
Configure the Redundancy Modules Chapter 6 Table 19 - Synchronization Interpretation Cause Cause Interpretation Module Qual Request Synchronization was aborted because another synchronization request was received. The current synchronization has stopped so that the new synchronization request can be serviced. SYS_FAIL_L Deasserted Synchronization was aborted because one of the modules came out of a faulted or failed state.
Page 120: Event Log Tab
Chapter 6 Configure the Redundancy Modules Event Log Tab The Event Log tab provides a history of events that have occurred on the redundant chassis. These system events are indicated in the event logs: • Qualification stages entered and completed •...
Page 121: Event Classifications
Configure the Redundancy Modules Chapter 6 Event Classifications Each event identified and logged is classified. You can use these classifications to identify the severity of the event and determine if additional action is required. Figure 30 - Event Classifications in the Event Log Tab Event Classifications Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 122 Chapter 6 Configure the Redundancy Modules Use this table to determine what an event classification indicates and if corrective action is required. Table 21 - Classification Types Classification Type Description Action Required Configuration A redundancy module configuration parameter has been changed. No corrective action is required.
Page 123: Access Extended Information About An Event
Configure the Redundancy Modules Chapter 6 Access Extended Information About an Event Events logged in the Event Log tab can have additional information available. To access additional information about an event, double-click an event listed in the log. Double-click to open extended information. Scroll to view details of other events.
Page 124: Interpret An Event's Extended Information
Chapter 6 Configure the Redundancy Modules Interpret an Event’s Extended Information The information listed in this table can be provided (depending on the type of event) after you have accessed the Extended Information Definition dialog box. Information Type Description Event Information The enhanced redundancy system assigns this event information: •...
Page 125 Configure the Redundancy Modules Chapter 6 3. In the Auto-Update area, click Off to keep the log from updating. 4. In the Partner Log area, click Close. This closes the event log of the partner module. 5. Select a single event or multiple events for which you want to export data. To select multiple events, select a start event, press SHIFT, and select an end event.
Page 126 Chapter 6 Configure the Redundancy Modules 8. Click Export. The event log is exported. The log can take a few minutes to export. 9. If you want to export the secondary redundancy module log for a complete system view complete step 1…step If you are exporting event data to provide to Rockwell Automation Technical IMPORTANT...
Page 127 Configure the Redundancy Modules Chapter 6 Export All Use this feature to automatically export all the available event log data for events in both of the redundancy modules of the redundant chassis pair. We recommend that you use this feature when troubleshooting system related anomalies, where the location of a fault could have occurred a lengthy period of time before the current event.
Page 128 Chapter 6 Configure the Redundancy Modules 7. Click Export. The event log is exported. The log can take a few minutes to export. Wait for this dialog box to appear. A .csv and a .dbg file is in the folder location specified. Make sure to provide both these files to Rockwell Automation Technical Support when troubleshooting an anomaly.
Page 129: Clear A Fault
Configure the Redundancy Modules Chapter 6 Clear a Fault You can use the Clear Fault feature on the Event Log tab to clear major faults that occur on a redundancy module. With this feature, you can remotely restart the redundancy module without physically removing and reinserting it from the chassis.
Page 130: System Update Tab
Chapter 6 Configure the Redundancy Modules System Update Tab Use of the commands in the System Update tab lets you perform firmware updates in the secondary chassis while the primary chassis remains in control. Reference the lock and switchover logs in this tab for update information when completing a firmware update.
Page 131: System Update Commands
Configure the Redundancy Modules Chapter 6 System Update Commands The three system update commands are available only when accessing a primary redundancy module. These commands are not available when accessing the secondary redundancy module. While you are completing tasks to update the system by using the system update commands, you cannot access these tabs in the RMCT: •...
Page 132 Chapter 6 Configure the Redundancy Modules Clicking the Lock for Update command initiates the locking process. The lock can take several minutes to finish. Monitor the System Update Lock Attempts log to determine when the lock is complete. In addition, the chassis status shown at the bottom-left of the dialog box changes from Primary with Disqualified Secondary to Primary Locked for Update.
Page 133 Configure the Redundancy Modules Chapter 6 Initiate Locked Switchover The Initiate Locked Switchover command is available only when the chassis redundancy state is Primary with Locked Secondary. That is, the Initiate Locked Switchover is available only after the lock for update is complete. Clicking Initiate Locked Switchover results in your secondary chassis assuming control and becoming the new primary.
Page 134: System Update Lock Attempts
Chapter 6 Configure the Redundancy Modules System Update Lock Attempts The System Update Lock Attempts is where attempts to lock the system are logged. This log displays the last four lock attempts and provides this information specific to each attempt: •...
Page 135: Locked Switchover Attempts
Configure the Redundancy Modules Chapter 6 Locked Switchover Attempts The Locked Switchover Attempts log provides information about the status of the last four locked switchover attempts. This log includes this information about each attempt: • Time and date • Status •...
Page 136: System Event History
Chapter 6 Configure the Redundancy Modules System Event History The System Event History tab provides a log of the last 10 major system events. The events logged here provide information specific to qualification, disqualification, switchovers, and redundancy module faults. For each event logged, this information is provided: •...
Page 137: Edit A User Comment For A System Event
Configure the Redundancy Modules Chapter 6 Edit a User Comment for a System Event To edit the User Comment associated with a system event, select the event and then click Edit. Then type your event description and click Accept Edit. Save System Event History If you want to save the system event log to the nonvolatile memory of the redundancy module, click Save System History at the bottom of the System Event...
Page 138: Using Dual Fiber Ports With The 1756-Rm2/A Redundancy Module
Chapter 6 Configure the Redundancy Modules Using Dual Fiber Ports with The dual fiber ports of the 1756-RM2/A module constitute a redundant pair of communication channels between the partner 1756-RM2s in a redundant chassis the 1756-RM2/A Redundancy pair. One of the channels is termed as ' A CTIVE' , while the other channel is Module termed as 'REDUNDANT' .
Page 139: Monitoring And Repair
Configure the Redundancy Modules Chapter 6 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.
Page 140 Chapter 6 Configure the Redundancy Modules Notes: Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 141: Program The Redundant Controller
Chapter Program the Redundant Controller Topic Page Configure the Redundant Controller Crossloads, Synchronization, and Switchovers Crossloads and Scan Time Program to Minimize Scan Times Program to Maintain Data Integrity Program to Optimize Task Execution Program to Obtain System Status Program Logic to Run After a Switchover Use Messages for Redundancy Commands Set the Task Watchdog Download the Project...
Page 142 Chapter 7 Program the Redundant Controller 3. Click the redundancy tab and check Redundancy Enabled. 4. If you are going to complete edits to your redundant controller while online, see these sections for information about the parameters available in the Advanced settings: •...
Page 143 Program the Redundant Controller Chapter 7 Verify this is not checked. You have completed the minimum configuration required for your redundant controllers. Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 144: Crossloads, Synchronization, And Switchovers
Chapter 7 Program the Redundant Controller Crossloads, Synchronization, Crossloading and synchronization points are points where the primary controller transfers data to the secondary controller. Crossload and synchronization points and Switchovers keep the secondary controller ready to assume control in the event of a fault on the primary.
Page 145: Default Crossload And Synchronization Settings
Program the Redundant Controller Chapter 7 Default Crossload and Synchronization Settings The default setting for a program in a redundant project is for a crossload to occur at the end of each program execution. However, for an equipment phase, the default is that the crossload not execute at the end of the phase. Before you change the default crossload and synchronization settings, read the sections that follow so you have a complete understanding of the implications.
Page 146 Chapter 7 Program the Redundant Controller Continuous Task with Crossloads at Each Program End This diagram demonstrates how programs set to crossload and synchronize at each program-end are executed after a switchover. As is shown, the new primary controller begins executing at the beginning of the program that was interrupted by the switchover.
Page 147: Multiple Periodic Tasks
Program the Redundant Controller Chapter 7 Multiple Periodic Tasks ATTENTION: If you use multiple periodic tasks, program all crucial outputs within the highest-priority task. Failure to program outputs in the highest-priority task can result in outputs changing state if a switchover occurs.
Page 148 Chapter 7 Program the Redundant Controller The diagram below shows a lower priority task that has not been completed and a switchover occurs. The lower priority task and programs are executed from the beginning of the program where the switchover occurred. This is because the program uses the default configuration and crossloads and synchronization points occur at the end of each program.
Page 149: Crossloads And Scan Time
Program the Redundant Controller Chapter 7 Crossloads and Scan Time It is important to plan for controller crossloads because the length of the crossloads affects the scan time of your program. A crossload is a transfer of data from the primary controller to the secondary controller and may occur at the end of each program or at the end of the last program in a task.
Page 150: Redundancy Object Attributes For Crossload Times
Chapter 7 Program the Redundant Controller Redundancy Object Attributes for Crossload Times Before you complete calculations to estimate the crossload time, you need to use a Get System Value (GSV) instruction to read certain attributes of the redundancy object. These attributes are data transfer sizes measured in DINTs (4-byte words) and are used to calculate the estimated crossload time.
Page 151: Equation For Estimating Crossload Times
Crossload time per sync point (ms) = (DINTs * 0.000275) + 0.54 ms Crossload time per sync point (ms) = (DINTs 0.00043) + 0.3 ms 1756-RM/B Crossload time per sync point (ms) = (DINTs  0.00091) + 0.6 ms 1756-RM/A Where DINTs is the size of the data transferred measured in 4-byte words.
Page 152: Program To Minimize Scan Times
Chapter 7 Program the Redundant Controller Program to Minimize Scan Because your system switchover time is impacted by your total program scan time, there are several aspects of your program that must be as efficient as possible Times to facilitate the fastest possible switchover. The sections that follow indicate methods of making your program more efficient to minimize your program scan time.
Page 153: Minimize The Number Of Programs
Program the Redundant Controller Chapter 7 Minimize the Number of Programs When programming a redundant controller, use the fewest programs possible. Using the fewest programs possible is especially important if you plan to crossload data and synchronize the controllers after the execution of each program.
Page 154: Manage Tags For Efficient Crossloads
Chapter 7 Program the Redundant Controller Manage Tags for Efficient Crossloads To program for more efficient crossloads of data and to reduce the amount of time required for a crossload to execute, manage your data tags as recommended in these sections. Delete Unused Tags Deleting unused tags reduces the size of the tag database.
Page 155 Program the Redundant Controller Chapter 7 Group Data Types Together in User-Defined Data Types When you create a User-Defined Data Type for use in your redundancy program, group like data types together. Grouping like data types compresses the data size and helps reduce the amount of data transferred during a crossload.
Page 156 Chapter 7 Program the Redundant Controller For example, if your application uses DINTs that you use only as constants to initialize your logic, BOOLs that you update every scan, and REALs that you update every second, you can create a separate User-Defined Data Type for each type of tag that is used at different points in the application.
Page 157: Use Concise Programming
Program the Redundant Controller Chapter 7 Use Concise Programming Use these recommendations to create concise programming. Using concise programming makes your program execute faster and reduces your program scan time. Execute an Instruction Only when Needed We recommend that you execute instructions only when needed because each time an instruction writes a value to a tag, the tag is crossloaded to the secondary controller.
Page 158 Chapter 7 Program the Redundant Controller In addition to using preconditions, try to group instructions that can be preconditioned by the same instructions together. In this example, the four preconditions used in the two branches can be combined to precede the two branches.
Page 159: Program To Maintain Data Integrity
Program the Redundant Controller Chapter 7 Program to Maintain Data When programming your redundant controllers, there are some instructions and techniques that may cause data loss or corruption when used. These instructions Integrity and techniques include the following: • Array (File)/Shift Instructions •...
Page 160: Scan-Dependent Logic
Chapter 7 Program the Redundant Controller Buffering Critical Data If you cannot place Array (File)/Shift instructions in the highest-priority task, consider using a buffer with Copy File (COP) and Synchronous Copy File (CPS) instructions to maintain the integrity of the array of data. The programming example shown here shows the use of a COP instruction to move data into a buffer array.
Page 161 Program the Redundant Controller Chapter 7 For example, if a higher priority task interrupts the logic shown in this example, the value of scan_count.ACC is sent to the secondary controller at the end of the program in the higher priority task. If a switchover occurs before the primary controller completes the EQU instruction, the new primary controller starts its execution at the beginning of the program and the EQU instruction misses the last value of scan_count.ACC.
Page 162 Chapter 7 Program the Redundant Controller Bind Dependent Instructions with UID and UIE Instructions If you cannot place scan-dependent instructions in the highest priority task, consider using the User Interrupt Disable (UID) and User Interrupt Enable (UIE) to prevent a higher priority task from interrupting the scan-dependent logic.
Page 163: Program To Optimize Task Execution
Program the Redundant Controller Chapter 7 Program to Optimize Task To make synchronization, crossloads, and HMI updates as fast as possible, make adjustments to the System Overhead Time Slice and the type of tasks used. These Execution adjustments affect service communication tasks that take place during the time when the continuous task is not executing.
Page 164: Specify A Larger System Overhead Time Slice
Chapter 7 Program the Redundant Controller Specify a Larger System Overhead Time Slice The system overhead time slice specifies the percentage of time the controller devotes to servicing communication, excluding the time for periodic tasks. The controller interrupts the continuous task to service communication, and then resumes the continuous task.
Page 165 Program the Redundant Controller Chapter 7 System Overhead Time Slice Examples This diagram illustrates a system where the System Overhead Time Slice is set to 20% (default). With this percentage, communication is serviced after every 4 ms of continuous task execution. Communication is serviced for up to 1 ms before the continuous task is restarted.
Page 166: Change The System Overhead Time Slice
Chapter 7 Program the Redundant Controller Change the System Overhead Time Slice To change the System Overhead Time Slice, access the Controller Properties dialog box and click the Advanced tab. You can enter your System Overhead Time Slice value. Options for During the Unused System Overhead Time Slice Enable the Run Continuous Task option (default setting) if you want the controller to revert to running the continuous task as soon as the communication servicing task has no pending activity.
Page 167: Use Periodic Tasks
Program the Redundant Controller Chapter 7 Use Periodic Tasks If you have multiple tasks in your project, changing the System Overhead Time Slice does not affect how communication is serviced. To increase the time to service communication when multiple tasks are used, configure the periodic tasks such that more time might be available to service communication.
Page 168: Program To Obtain System Status
Chapter 7 Program the Redundant Controller Example of Periodic Task Configurations Task Priority Execution Time Period Specified Higher 20 ms 80 ms Lower 30 ms 100 ms Total execution time: 50 ms In this example, the execution time of the highest priority task (Task 1) is significantly smaller than its period, that is, 20 ms is less than 80 ms, and the total execution time of all the tasks is significantly smaller than the specified period of the lowest priority task, that is, 50 ms is less than 180 ms.
Page 169 Program the Redundant Controller Chapter 7 In the example below, the GSV instruction is used to obtain the chassis ID (that is, the chassis A or B designation) of the chassis that is functioning as the primary. value is stored in the tag.
Page 170: Program Logic To Run After A Switchover
Chapter 7 Program the Redundant Controller Program Logic to Run After a If your application requires certain logic or instructions to be executed after a switchover, then use programming and tags similar to that shown in this example. Switchover Figure 52 - Precondition Used to Run Logic After Switchover - Ladder Logic Add your switchover-dependent instructions here.
Page 171: Use Messages For Redundancy Commands
Program the Redundant Controller Chapter 7 Use Messages for For some applications, you may want to program the controller to issue redundancy system commands via the redundancy modules. The sections that Redundancy Commands follow explain how to configure a MSG instruction to issue a redundancy command.
Page 172: Configure The Msg Instruction
INT tag with a value of 1 Source Length Destination Element None - no value needed. Communication Path Browse for the path to the 1756-RM or 1756-RMXT redundancy module. Connected box Leave the Connected checkbox unchecked. Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 173 Program the Redundant Controller Chapter 7 Use this table to when using MSG instructions during a switchover. Table 30 - MSG Instruction Behavior During a Switchover If the MSG instruction Then From a redundant controller In a redundant controller, any MSG instruction that is in progress during a switchover experiences an error. (The ER bit of the instruction turns on.) After the switchover, normal communication resumes.
Page 174 Source Length Destination Element None - no value needed. Communication Path Browse for the path to the 1756-RM or 1756-RMXT redundancy module. Connected box Leave the Connected checkbox unchecked. Synchronize the Secondary Chassis To disqualify the secondary controller, use the MSG instruction parameters listed in this table.
Page 175: Set The Task Watchdog
Program the Redundant Controller Chapter 7 Set the Redundancy Module Date and Time To set the wallclock time of the 1756-RM module, use the MSG instruction parameters listed in this table. Table 33 - Set Wallclock Time In this tab...
Page 176 Chapter 7 Program the Redundant Controller We recommend that you reevaluate the watchdog times in your application if either of these events occur: • A second controller is added to a redundancy chassis. • The application in a second controller that is already in the system is modified.
Page 177: Minimum Value For The Watchdog Time
Program the Redundant Controller Chapter 7 Minimum Value for the Watchdog Time To set Watchdog time for your 1756-L6x controllers, use this table to determine which equation to use to calculate the time for each task. Then use this equation Using ControlNet I/O ms (2 * maximum_scan_time) + 150 Using Ethernet I/O ms...
Page 178: Store A Redundancy Project To Nonvolatile Memory
Chapter 7 Program the Redundant Controller Store a Redundancy Project Use this procedure to store an updated project and firmware to the nonvolatile memory card of the controller. to Nonvolatile Memory The controllers use these nonvolatile memory cards. IMPORTANT Cat. No. Nonvolatile Memory Card 1756-L6x 1784-CF64 or 1784-CF128 CompactFlash cards...
Page 179: Remote Program Mode
2. Use RSLogix 5000 software or the mode switch to put the primary controller into Program or Remote Program mode. 3. In RSLinx Classic communication software, right-click the 1756-RM module and choose Module Configuration to open the RMCT. 4. In the Configuration tab, set the Auto-Synchronization parameter to Conditional.
Page 180 Chapter 7 Program the Redundant Controller 5. On the Synchronization tab, click Disqualify Secondary. 6. In RSLogix 5000 software, access the Controller Properties dialog box and click the Nonvolatile Memory tab. 7. Click Load/Store. 8. Click <-- Store and then click Yes. When the store is complete, we go online with the secondary controller.
Page 181: Store A Project While A System Is Running
Program the Redundant Controller Chapter 7 Store a Project While a System is Running If you want to store your controller project in nonvolatile memory while your redundant system is running, complete these steps. 1. Verify that the redundant chassis are synchronized. 2.
Page 182: Load A Project
Chapter 7 Program the Redundant Controller Load a Project If you need to load a project from nonvolatile memory, you must first disqualify your redundancy system. You then load the project from the primary controller and resynchronize the redundant chassis once the load is complete. For details about loading a project from nonvolatile memory, see the Logix5000 Controllers Memory Card Programming Manual, publication 1756-PM017.
Page 183: Plan For Test Edits
Program the Redundant Controller Chapter 7 • A PIO to a primary controller may fail if a switchover occurs while the PIO is still in process. When the anomaly occurs and the PIO fails, you may see any of these errors: –...
Page 184 Chapter 7 Program the Redundant Controller Use this table to determine the Retain Test Edits on Switchover setting that suits your application. If you need to Then Prevent a test edit from faulting both the primary and secondary Leave Retain Test Edits on Switchover controller unchecked Keep test edits active, even in the event of a switchover and at the risk...
Page 185 Program the Redundant Controller Chapter 7 When using a 1756-L7x redundancy controller using version 19 software, and IMPORTANT the Memory Usage slider is set all the way to Tags, the first synchronization attempt will be successful, but after switchover or disqualification, the next qualification attempt will fail, and one or more entries will appear in the secondary redundancy module event log with the following description: ‘(14) Error Setting Up Data Tracking.’...
Page 186: Finalize Edits With Caution
Chapter 7 Program the Redundant Controller Finalize Edits with Caution When you finalize edits to your program while online, the original program that existed before the changes were made is deleted. As a result, if the edits you finalize cause a fault on the primary controller, the new primary controller will also fault after the switchover.
Page 187: Reserve Memory For Tags And Logic
Program the Redundant Controller Chapter 7 Reserve Memory for Tags and Logic Depending on your redundant application, you may need to change the memory usage property for your redundant controller. The setting you specify impacts how the controller divides memory for tags and logic to be stored to the buffer during a crossload to the secondary controller.
Page 188 Chapter 7 Program the Redundant Controller Notes: Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 189: Monitor And Maintain An Enhanced Redundancy System
Chapter Monitor and Maintain an Enhanced Redundancy System Topic Page Tasks to Monitor the System Controller Logging Use Programming to Monitor System Status Verify Date and Time Settings Verify System Qualification Check the ControlNet Module Status Tasks to Monitor the System This chapter describes some of the key tasks to complete to monitor and maintain your enhanced redundancy system.
Page 190: Controller Log
Chapter 8 Monitor and Maintain an Enhanced Redundancy System Controller Log A controller log is the record of changes. The log is stored on the controller’s NVS memory automatically. You can store the log to a CF card or SD card on an as needed basis or automatically at predefined times.
Page 191: Verify Date And Time Settings
Monitor and Maintain an Enhanced Redundancy System Chapter 8 Verify Date and Time After you have completed programming your redundant system and have downloaded your program to the primary controller, check the Redundancy Settings Module Date and Time information and verify it matches the date and time of your system.
Page 192: Verify System Qualification
Chapter 8 Monitor and Maintain an Enhanced Redundancy System Verify System Qualification After you have completed programming your redundant system and have downloaded your program to the primary controller, check the system status to verify that the system is qualified and synchronized. The system qualification process can take several minutes.
Page 193 Monitor and Maintain an Enhanced Redundancy System Chapter 8 Example of Qualified and Disqualified Status Indicators This example shows status display messages and status indicators that may appear differently depending on the qualification status of the redundant chassis. Note that these are only two examples of many possible status display message and indicator combinations for both the qualified and disqualified states.
Page 194: Check Qualification Status Via The Rmct
Chapter 8 Monitor and Maintain an Enhanced Redundancy System Check Qualification Status via the RMCT To determine the qualification status of your system by using the RMCT, open the RMCT and view the qualification status in the bottom-left corner of the tool.
Page 195: Conduct A Test Switchover
Monitor and Maintain an Enhanced Redundancy System Chapter 8 Conduct a Test Switchover Complete these steps to verify that your redundant system switches over as expected. Your system must be fully-qualified before you begin. 1. In RSLinx Classic software, access the RMCT for the primary redundancy module.
Page 196: Synchronization After A Switchover
Chapter 8 Monitor and Maintain an Enhanced Redundancy System Synchronization After a Switchover If your Auto-Synchronization parameter is set to Always, your system begins synchronizing immediately after the switchover. To monitor the synchronization of your system after you initiate the test switchover, you can monitor the synchronization process by using these methods: •...
Page 197: Check The Controlnet Module Status
Monitor and Maintain an Enhanced Redundancy System Chapter 8 Check the ControlNet Module After you have programmed your redundant system and configured your ControlNet network, check two statistics specific to your ControlNet modules. Status These statistics include the CPU usage and the connections used. To view the CPU usage and the number of connections used, complete these steps.
Page 198: Cpu Usage
Chapter 8 Monitor and Maintain an Enhanced Redundancy System CPU Usage The CPU usage of the ControlNet modules must be at 80%, or less. Keeping the CPU usage below 80% reserves enough CPU functionality for the ControlNet module to properly facilitate a switchover. If the CPU usage is above 80%, the secondary chassis may not be able to synchronize with the primary chassis after a switchover occurs.
Page 199: Troubleshoot A Redundant System
Chapter Troubleshoot a Redundant System Topic Page General Troubleshooting Tasks Check the Module Status Indicators Use RSLogix 5000 Software to View Errors Use the RMCT for Synchronization Attempts and Status Use the RMCT Event Log Keeper Status Causing Synchronize Failure Partner Network Connection Lost Redundancy Module Connection Lost Redundancy Module Missing...
Page 200: Check The Module Status Indicators
Figure 58 - Steady or Flashing Red Indicators that Indicate Errors on 1756-RM2/A or 1756-RM2XT Modules CH2 CH1 OK Figure 59 - Steady of Flashing Red Indicators that Indicate Errors on 1756-RM/1756-RMXT Modules PRI COM OK For more information about module status indicators, see...
Page 201: Use Rslogix 5000 Software To View Errors
Troubleshoot a Redundant System Chapter 9 Use RSLogix 5000 Software To view redundancy status by using RSLogix 5000 software, complete these steps. to View Errors 1. Go online with the redundant controller. 2. Either click Primary or Secondary, depending on the controller you are online with.
Page 202 Chapter 9 Troubleshoot a Redundant System 3. If further information is required, click Controller Properties. 4. Click the Redundancy tab. 5. If controller fault details are needed, click the Major Faults and Minor Faults tabs to view fault types and codes. Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 203: Redundant Controller Major Fault Codes
Troubleshoot a Redundant System Chapter 9 6. If necessary, reference these resources: • Redundant Controller Major Fault Codes • Logix5000 Controllers Major and Minor Faults programming manual, publication 1756-PM014 (describes all major and minor fault codes) Redundant Controller Major Fault Codes The fault codes listed and described in this table are specific to redundant controllers.
Page 204: Use The Rmct For Synchronization Attempts And Status
Chapter 9 Troubleshoot a Redundant System Use the RMCT for When troubleshooting your redundant system for anomalies with qualification and synchronization, check the Synchronization and Synchronization Status tabs Synchronization Attempts of the RMCT. and Status Recent Synchronization Attempts The Synchronization tab provides a log of the last four synchronization attempts. If a synchronization command was unsuccessful, the Recent Synchronization Attempts log indicates a cause.
Page 205: Module-Level Synchronization Status
Troubleshoot a Redundant System Chapter 9 Module-level Synchronization Status The Synchronization Status tab provides a module-level view of redundant chassis and can be used to identify what module pair may be causing a synchronization failure. Depending on the type of synchronization failure, you may need to open the Synchronization Status tabs for the primary and secondary redundancy modules.
Page 206: Use The Rmct Event Log
Chapter 9 Troubleshoot a Redundant System Use the RMCT Event Log When troubleshooting your redundant system, access the Event Log to determine the cause of an event, error, switchover, or major fault. Interpret Event Log Information Use this procedure to view and interpret Event Log information. 1.
Page 207 Troubleshoot a Redundant System Chapter 9 2. If an event occurred, open the Event Log for both chassis (A and B). 3. Locate the Event line that shows the qualification code, start date and time of the event, in the A chassis event log. This is the last time the redundancy module was working properly.
Page 208 Chapter 9 Troubleshoot a Redundant System 5. Work back in time (up the lines of preceding events), to locate the point that a switchover or disqualifying event occurred. This is the end date and time of the event, and will be indicated on the Event line in the A chassis event log, with a disqualification code that the secondary has been disqualified, and a corresponding disqualification code in the B chassis event log.
Page 209 Troubleshoot a Redundant System Chapter 9 6. Examine the range of time in between the start of the event and the end of the event to find the error that caused the disqualification. Be aware that this range of time can be very large depending on how much IMPORTANT time has passed since the last disqualifying event.
Page 210 Chapter 9 Troubleshoot a Redundant System You can also use the Log Time column to identify a significant event. Scan within a time range that corresponds to the time an event was reported or annunciated. In addition, you can also attempt to identify events by finding differences between times logged.
Page 211: Export All Event Logs
Primary with no secondary partner Export All Event Logs To export event logs with the RMCT version 8.01.05, follow these steps. 1. Open the RMCT on the 1756-RM module in the primary chassis and click the Event Log tab. 2. Click Export All.
Page 212 4. To change the file name or save location to something other than the default, select the Browse button. 5. Click Export. 6. Select the 1756-RM in the secondary chassis. In the following example, chassis A is the secondary chassis. The primary chassis exports first.
Page 213 Troubleshoot a Redundant System Chapter 9 In the following example, chassis B is the primary chassis. The secondary chassis then exports. In the following example, chassis A is the secondary chassis. A confirmation dialog box displays when the export completes. 7.
Page 214: Export Diagnostics
Chapter 9 Troubleshoot a Redundant System Export Diagnostics Only Export Diagnostics when requested to do so by Rockwell Automation IMPORTANT Technical Support. You can also click Export Diagnostics in the event of a module fault in the 1756 redundancy module. Click Export Diagnostics to collect and save diagnostic data from the redundancy module and its partner, if an unrecoverable firmware fault occurs.
Page 215 Troubleshoot a Redundant System Chapter 9 The Export Diagnostics dialog box appears, asking you to continue specifying a communication path. 3. Click OK to specify the communication path via RSWho software. The RSWho window appears. 4. Select the communication path to the partner or secondary module and click OK.
Page 216: Contact Rockwell Automation Technical Support
Chapter 9 Troubleshoot a Redundant System 5. Name and save the export file. 6. Click Export. It may take several minutes to export all of the data. The Export Diagnostic Complete dialog box appears once the export has completed. 7. Click OK. Forward this diagnostics file to Rockwell Automation Technical Support only if requested to do so.
Page 217: Check The Module Status Display
Troubleshoot a Redundant System Chapter 9 Check the Module Status Display If the module status display of the ControlNet modules in the redundant chassis indicate these errors, you need to take corrective action: • Keeper: Unconfigured • Keeper: Unconfigured (data format changed) •...
Page 218: Valid Keeper Status And Signatures
Chapter 9 Troubleshoot a Redundant System Valid Keepers and Signatures This example shows a Keeper Status dialog box where the ControlNet network that is comprised of valid keepers and signatures. Valid Keeper Status and Signatures Unconfigured Keeper The example below shows the Keeper Status dialog box where a module has an unconfigured status.
Page 219 Troubleshoot a Redundant System Chapter 9 Keeper Signature Mismatch This example shows ControlNet modules in the redundant chassis that do not have the same keeper signatures. With this anomaly, the ControlNet module display indicates Keeper: Signature Mismatch. This anomaly may result if a ControlNet module configured for the same node of another network is used to replace a ControlNet module with the same node address in the redundant chassis.
Page 220: Partner Network Connection Lost
Chapter 9 Troubleshoot a Redundant System Partner Network Connection If a partner network connection between a redundant chassis pair is lost, a state change or switchover may occur. These state changes may result: Lost • Primary with qualified secondary changes to primary with disqualified secondary •...
Page 221 Troubleshoot a Redundant System Chapter 9 4. Use the time of the switchover event found in the primary chassis to identify the corresponding event in the secondary chassis. The switchover indicated in the primary chassis log occurred at 10:27:08. Secondary Chassis Event Log The corresponding events in the secondary chassis log indicate that the network is not attached and that the SYS_FAIL_LActive backplane signal is active.
Page 222: Redundancy Module Connection Lost
Chapter 9 Troubleshoot a Redundant System To recover from a ControlNet network disconnection, take these actions: • Check all ControlNet tap and trunkline connections. Correct any disconnections or other connection anomalies. • If the Auto-Synchronization parameter is not set to Always, use the commands in the Synchronization tab of the RMCT to synchronize your chassis.
Page 223: Redundancy Module Missing
Troubleshoot a Redundant System Chapter 9 To resolve this anomaly, check the intermodule cable that connects the redundancy modules. Verify that it is properly connect and is not severed. Also, if the Auto-Synchronization parameter of this system is not set to always, use the commands in the Synchronization tab to synchronize that chassis once the anomaly is resolved.
Page 224 Chapter 9 Troubleshoot a Redundant System You can also browse to the redundancy module in RSLinx Classic software to determine if it is connected to the network. A red X over the redundancy module indicates the module is not in the chassis. Figure 66 - Missing Redundancy Module in RSLinx Classic Software To correct the missing module anomaly, first verify that the redundancy module is correctly installed in the chassis and it is properly powered.
Page 225: Qualification Aborted Due To A Nonredundant Controller
Troubleshoot a Redundant System Chapter 9 Qualification Aborted Due to If you place a controller that is not enabled for redundancy into the redundant chassis, the qualification and synchronization fail. To determine if your a Nonredundant Controller synchronization failure is due to a nonredundant controller, complete these steps. 1.
Page 226: Controller Events
Chapter 9 Troubleshoot a Redundant System 5. Open RSLogix 5000 and go online with the primary controller in your system. 6. Open the controller properties and verify that Redundancy Enabled is checked. This controller is not enabled for use in a redundant system.
Page 227: Redundancy Module Status Indicators
Appendix Status Indicators Topic Page Redundancy Module Status Indicators Redundancy Module Status The redundancy modules have these diagnostic status indicators. Indicators 1756-RM2/A and 1756-RM2XT Status Indicators Figure 67 - Redundancy Module Status Indicators for 1756-RM2/A and 1756-RM2XT Modules P R I M CH2 CH1 OK CH2 CH1 OK Module Status Display...
Page 228 Appendix A Status Indicators Table 40 - Module Status Display Module Status Display Description PRIM Primary redundancy module. The module is operating as the primary module. No action required. DISQ Disqualified secondary redundancy module. Check the secondary partner module’s type and revision. QFNG Qualifying secondary redundancy module.
Page 229 Status Indicators Appendix A OK Status Indicators The OK status indicator reveals the current redundancy module state. Table 41 - OK Status Indicator Indicator State Description No power is applied to the redundancy module. If necessary, apply power. Solid red One of these conditions exists: •...
Page 230: 1756-Rm/A And 1756-Rm/B Status Indicators
CH2 status indicator shows solid red and the RMCT software displays the following error message in the status bar at the bottom of the screen: ‘SFP !Cpt.’ 1756-RM/A and 1756-RM/B Status Indicators Figure 68 - Redundancy Module Status Indicators for 1756-RM and 1756-RMXT Modules P R I M Module Status Display...
Page 231 Status Indicators Appendix A Table 43 - Module Status Display Module Status Display Description PROG Boot mode - Updating redundancy module firmware. Wait for firmware update to finish. No action is required. ???? Resolving initial redundancy module state. Wait for state resolution to finish. No action is required. PRIM Primary redundancy module.
Page 232 Appendix A Status Indicators OK Status Indicators The OK status indicator reveals the current redundancy module state. Table 44 - OK Status Indicator Indicator State Description No power is applied to the redundancy module. If necessary, apply power. Solid red One of these conditions exists: •...
Page 233: Redundancy Module Fault Codes And Display Messages
Status Indicators Appendix A Chassis State Status Indicator The Chassis State (PRI) status indicator identifies whether the chassis is primary. The PRI status indicator on the primary redundancy module remains solid green, and the PRI status indicator on the secondary redundancy module remains off. Redundancy Module Fault Codes and Display Messages Redundancy modules may experience any of these faults.
Page 234 Appendix A Status Indicators Module Status Display A character string scrolls across the Module Status Display to indicate the fault type. The character string displays the fault type in either of these ways: • Two to four-character word abbreviations • Alpha numeric codes This table describes the two to four-character word abbreviations.
Page 235: Recovery Messages
Status Indicators Appendix A Table 48 describes the alphanumeric codes. The fault code is a four-character alphanumeric string. Valid characters are 0 … and A through Z, except S and O. The first character is always E. Each firmware subsystem within the redundancy module is assigned a range of fault codes. Each subsystem assigns fault codes within its range.
Page 236 Appendix A Status Indicators Notes: Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 237: Event Log Descriptions
Module insertion The 1756-RM now sees the module on the backplane. This means the module has either just powered up, just been put into the chassis, or just finished resetting. Double click the event to see the slot number of the module.
Page 238 1756-RM serial number rule A check to choose a primary chassis if both chassis power up at the same time. This is the final tie-breaker. The 1756-RM with the lower serial number gets the first chance to become primary. It becomes primary as long as the other chassis isn't more able to control the system.
Page 239: Upgrade From A Standard Redundancy System
Before you begin upgrading from a standard redundancy system to an enhanced redundancy system, consider these points: • If the standard redundancy system uses a 1757-SRM redundancy module, you must replace it with a 1756-RM redundancy module. • You must upgrade all ControlNet or EtherNet/IP communication modules.
Page 240: Upgrade System Components
Appendix C Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Upgrade System Components Safely shut down system and controlled equipment. IMPORTANT Be sure to place the system and controlled equipment in a state where they can be safely shut down prior to beginning this upgrade. The available components to which you can upgrade when converting a standard redundancy system to an enhanced redundancy system depends on the enhanced redundancy system revision level.
Page 241: Upgrade The System Software
Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C Upgrade the System Software Upgrading your system software requires you to make many considerations and decisions. Make sure you are fully aware of how your specific application will be affected when you upgrade system software: •...
Page 242: Replace Communication Modules
Appendix C Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Replace Communication Modules You must replace all communication modules when upgrading to any enhanced redundancy system revision. You must use enhanced communication modules in an enhanced redundancy system. This table describes which controllers are available for system upgrades.
Page 243: Steps After System Components Upgrade
Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C Steps After System Components Upgrade Complete these remaining steps after upgrading the necessary components to an enhanced redundancy system 1. Apply power to the primary chassis. 2.
Page 244: Upgrade Ethernet Modules When Rotary Switches Are Set
Appendix C Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Upgrade Ethernet Modules This section includes the procedure to upgrade your Ethernet communication modules when the modules rotary switches are set to 2…254 and you are unable When Rotary Switches Are Set to interrupt the primary.
Page 245 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C 5. From the Auto-Synchronization pull-down menu, choose Never. 6. Click Apply, then click Yes. 7. Click the Synchronization tab. 8. Click Disqualify Secondary, then click Yes. The secondary chassis is disqualified as indicated by the RMCT at the bottom-left of the RMCT and on the redundancy module’s status display.
Page 246 Appendix C Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System 10. Make a note of the primary Ethernet module’s Port Configuration including the following: • IP Address • Network Mask • Gateway Address 11. Disconnect the Ethernet cable or cables from the secondary Ethernet module.
Page 247 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C b. Select the Ethernet module catalog number and click Next. c. Browse to the module and select it. Secondary Chassis d. Click OK. e. Select the firmware revision to upgrade to and click Next. f.
Page 248 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System 18. In RSLinx Classic software, browse in this chassis to the primary 1756-RM module. 19. Right-click to select Module Configuration to open the RMCT. 20. Click the Synchronization tab in the RMCT.
Page 249 Ethernet modules that have their rotary switches set between 2…254. 30. In RSLinx Classic software, browse to the primary 1756-RM module. 31. Right-click to select Module Configuration to open the RMCT. 32. Click the Synchronization tab in the RMCT.
Page 250: Upgrade By Using Redundancy System Update
Appendix C Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Upgrade by Using Redundancy You can upgrade an enhanced redundancy system revision to another while your process continues to run. This is known as Redundancy System Update (RSU). System Update RSU is available only when upgrading from an enhanced redundancy system revision IMPORTANT...
Page 251 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C Step 1: Before You Begin Consider these points before you begin upgrading your enhanced redundancy system to a new revision. • During the upgrade procedures, you cannot use RSLogix 5000 software to change the mode of the controller.
Page 252 Appendix C Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Step 3: Download and Install the Redundancy Firmware Bundle Download and install the redundancy firmware revision bundle from the Rockwell Automation Support website at: www.rockwellautomation.com/ support/ Follow these steps.
Page 253 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C The Module Configuration dialog box opens. 4. Right-click the title bar and select About. The About dialog box opens and indicates the RMCT version. The RMCT launches at the version that is compatible with the redundancy module firmware that is currently installed.
Page 254: Upgrade Ethernet Modules When Rotary Switches Are Set Between 2
Appendix C Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Step 6: Prepare the Redundant Chassis for the Firmware Upgrade Complete these steps to prepare both the primary and secondary redundant chassis for redundancy firmware upgrades. 1.
Page 255 Closing the RMCT helps prevent a timeout from occurring when the redundancy module’s firmware is upgraded. Step 7: Upgrade the Primary Chassis Redundancy Module Firmware Wait 45 seconds before you begin updating the 1756-RM firmware. During this time, the redundancy module conducts internal operations to prepare for an upgrade.
Page 256 Complete these steps to upgrade the firmware in the secondary chassis. 1. Launch ControlFLASH software and click Next. 2. Select the redundancy module catalog number and click Next. 1756-RM/B 1756-RM2/A Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 257 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C 3. Browse to the module and select it. Primary Chassis Secondary Chassis 4. Click OK. 5. Select the firmware revision to upgrade to and click Next. 6.
Page 258 Appendix C Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System 8. Complete steps 2…7 for each module in the secondary chassis, including a new controller, if applicable. IMPORTANT Ethernet communication modules that have rotary switches set must have been previously updated using Upgrade Ethernet Modules When Rotary Switches Are Set between 2…254 on page...
Page 259 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C 11. Click Change Controller. 12. Specify the controller revision to which you are upgrading. 13. If you installed a new controller while upgrading the primary chassis firmware, specify the new controller catalog number.
Page 260 Appendix C Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System You are now ready to lock the system and initiate a locked switchover to update the primary chassis. Continue with Step 10: Lock the System and Initiate a Switchover to Upgrade.
Page 261 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C The System Update Lock Attempts log indicates when the system lock is complete. 5. Click Initiate Locked Switchover, then click Yes. This step results in your secondary chassis assuming control and becoming the primary chassis.
Page 262 Appendix C Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System 1. If you are replacing and upgrading your controller hardware, remove the controller from the secondary chassis and replace it with the new controller. 2. Launch ControlFLASH software and click Next. 3.
Page 263 Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Appendix C Step 12: Synchronize the Redundant Chassis Complete these steps to synchronize the redundant chassis after firmware in both chassis have been upgraded to the same revision. 1.
Page 264: Replace 1756-Rm/A Or 1756-Rm/B Redundancy Modules With 1756-Rm2/A Redundancy Modules
Appendix C Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System Replace 1756-RM/A or 1756- If you need to replace your current redundancy modules with 1756-RM2/A modules, you can do so without initiating a switchover. RM/B Redundancy Modules with 1756-RM2/A For the following steps, ‘redundancy’...
Page 265 Appendix Convert from a Nonredundant System Topic Page Update the Configuration in RSLogix 5000 Software Replace Local I/O Tags Replace Aliases to Local I/O Tags Remove Other Modules from the Controller Chassis Add an Identical Chassis Upgrade to Enhanced Redundancy Firmware Update the Controller Revision and Download the Project When converting from a nonredundant to a redundant system, first consider the following:...
Page 266: Update The Configuration In Rslogix 5000 Software
Appendix D Convert from a Nonredundant System Update the Configuration in These steps provide an overview of the process required to update the I/O Configuration tree in RSLogix 5000 software. RSLogix 5000 Software 1. If you have I/O in the chassis with the controller, add a ControlLogix communication module to the appropriate network because I/O modules are not permitted in a redundant chassis.
Page 267 Convert from a Nonredundant System Appendix D 2. Copy the I/O modules and paste them into the chassis of the newly-added communication module. Paste I/O into the new ControlNet chassis. 3. Delete the I/O modules from the controller chassis configuration. 4.
Page 268: Replace Local I/O Tags
Appendix D Convert from a Nonredundant System Replace Local I/O Tags If you have moved I/O modules out of the local controller chassis and into the remote I/O chassis, complete these steps to find and replace the local I/O tags in your program.
Page 269: Replace Aliases To Local I/O Tags
Convert from a Nonredundant System Appendix D 9. Click Replace All. The find/replace is completed and the results are indicated in the Search Results tab. Replace Aliases to Local If your program uses alias tags for the I/O modules that you are moving, complete these steps to replace alias tags.
Page 270: Remove Other Modules From The Controller Chassis
ControlLogix controller   1756-L72, ControlLogix controllers 1756-L73, 1756-L74, 1756-L75  1756-L71   1756-L73XT ControlLogix-XT controller    Redundancy 1756-RM ControlLogix redundancy module modules    1756-RMXT ControlLogix-XT redundancy module Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 271: Add An Identical Chassis
Convert from a Nonredundant System Appendix D Add an Identical Chassis After you have configured your primary chassis with the modules listed above, add an identical chassis that contains the same modules with the same module- placement. For more information about chassis configuration, see the section titled Redundant Chassis on page Upgrade to Enhanced Once you have made the appropriate changes to your system configuration and...
Page 272 Appendix D Convert from a Nonredundant System Notes: Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 273: Redundancy Object Attributes
Appendix Redundancy Object Attributes Use this table of redundancy object attributes as a reference when programming to obtain the status of your redundancy system. For this information Get this attribute Data GSV/SSV Description Type Then Redundancy status of the entire ChassisRedundancyState chassis.
Page 274 Appendix E Redundancy Object Attributes For this information Get this attribute Data GSV/SSV Description Type Then Status of the synchronization Qualification InProgress (qualification) process. Synchronization (qualification) is not in progress. Unsupported 1 - 99 For modules that can measure their completion percentage, the percent of synchronization (qualification) that is complete.
Page 275 Unknown without regard to the state of the chassis. Chassis A Chassis B Slot number of the 1756-RM module 1756-RM SlotNumber in this chassis. • Size of the last crossload. LastDataTransfer Size DINT This attribute gives the size of data that was or would have been crossloaded in the last scan in the number of DINT’s (4-byte words).
Page 276 Appendix E Redundancy Object Attributes Notes: Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 277: Chassis Configuration Checklist
• ControlNet communication modules, catalog numbers 1756-CN2/B, 1756-CN2R/B, 1756-CN2RXT • EtherNet/IP communication modules, catalog numbers 1756-EN2T,1756-EN2TXT, 1756-EN2TR, 1756-EN2F • Redundancy modules, catalog numbers 1756-RM, 1756-RMXT, 1756-RM2/A, 1756-RM2XT Each chassis of the pair is comprised of identical modules that are of identical redundancy firmware revisions, series, and memory sizes.
Page 278: Remote I/O Checklist
• 1756-RMC10 (10 m, 32.81 ft) If necessary, you can make your own fiber-optic cable that is up to 4 km (13,123.36 ft) for the 1756-RM/B module or 10 km (32,808.40 ft) for the 1756-RM2 module. Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 279: Controllogix Controller Checklist
Enhanced Redundancy System Checklists Appendix F ControlLogix Controller Checklist  Requirement Identical ControlLogix controllers are placed in the same slot of both chassis of the redundant pair. Partnered controllers are identical in redundancy firmware revision, and memory size. Within each redundant chassis, one or two (maximum) of these controllers are used: •...
Page 280: Ethernet/Ip Module Checklist
Appendix F Enhanced Redundancy System Checklists  Requirement ControlNet HMI A ControlNet network or a ControlNet-to-EtherNet/IP gateway is used to connect to HMI because your system requires that HMI be updated immediately after a switchover. • PanelView Standard terminal, PanelView 1000e or 1400e terminal ...
Page 281: Project And Programming Checklist
Enhanced Redundancy System Checklists Appendix F  Requirement EtherNet/IP HMI HMI Blind Time is the time during a switchover from primary to secondary, when tag data from the controller is unavailable for reading or writing. See HMI Blind Time Reduction on Ethernet During a Switchover on page IMPORTANT: This feature requires RSLinx Enterprise software, version 5.50.04 or later.
Page 282 Appendix F Enhanced Redundancy System Checklists  Requirement Scan time is minimized by using these techniques when possible: • Unused tags are eliminated. • Arrays and user-defined data types are used instead of individual tags. • Redundancy data is synchronized at strategic points by using the Synchronize Data after Execution setting in the Program Properties dialog box. •...
Page 283 Appendix Enhanced Redundancy Revision History Changes to This Manual With the availability of new controllers, modules, applications, and RSLogix 5000 software features, this manual has been revised to include updated information. This appendix briefly summarizes changes that have been made with each revision of this manual.
Page 284 Appendix G Enhanced Redundancy Revision History Publication Revision and Date Topic Added firmware requirements for revisions 20.054 and 19.053Enh Added information to enhanced redundancy module quick start Added EDS files information Added communication module installation and1756-EN2F module information Updated controller installation information Updated redundancy module installation Updated fiber-optic communication cable connection Updated chassis firmware information...
Page 285 Support for 1756-L7x controllers Improved scan time with 1756-L7x controllers when compared to the scan time with 1756-L6x controllers Corrected MSG attribute value to set the date and time for a 1756-RM redundancy module Support for Partial Import online Support for controller logging...
Page 286 Appendix G Enhanced Redundancy Revision History Notes: Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 287 1756-L7x controller 29 1756-RM2/A 24 1756-L7xXT 25 1756-RM2XT/A 24 1756-RM components status indicators 200 enhanced redundancy system 24 1756-RM and 1756-RMXT modules 31 overview 17 1756-RM2/A 24 upgrade 240 1756-L7x 152 concise, program 157 compatible revisions 24 configuration crossload 151...
Page 288 Index ControlNet CPU usage 198 edit system event 137 keeper crossload 102 EDS files 54 keeper status 101 electrostatic discharge 58 module check status 197 elements of DLR network 87 monitor CPU usage 198 enable network update time 95 user program control 115 node requirements 38 enhanced redundancy system overview 38...
Page 289 Index export data for all events 127 IP address 52 export diagnostics button 214 BOOTP/DHCP utility 86 consecutive 78 export event log 124 plan 85 extended event information 123 RSLinx communication software 86 RSLogix 5000 software 86 set 86 swap 78 FactoryTalk software 16 swapping 36 switches 86...
Page 290 Index overview 35 scan time 149 keeper 101 enable user control 115 keeper crossload 102 finalize test edits 186 Remote I/O 42 logic after switchover 170 schedule maintain data integrity 159 existing 100 manage tags 154 new 98 messages for redundancy commands 171 Universal Remote I/O 43 update time 95 monitor system status 190...
Page 291 Index redundancy firmware remote controller bundles unicast 84 remove bundles redundant module 75 redundancy firmware replace redundancy modules 20 redundancy module 31 redundant module 75 connect via fiber-optic cable 63 replace communication module 242 date and time 115 requested packet interval info 111 over EtherNet/IP 77 install 57...
Page 292 SFP 67 of qualification 74 troubleshoot 199 via module status display 192 status indicators check status indicators 200 controller event 226 1756-RM 200 EtherNet/IP 1756-RM2/A 200 lost connection 220 1756-RM2XT/A 227 lost EtherNet/IP connection 220 CH1 229 missing redundancy module 223...
Page 293 Index upgrade components 240 version firmware 67 RMCT 109 Redundancy Module Configuration Tool 252 software 251 user comment 137 user program control 115 watchdog time 177 utilities workstation software 51 BOOTP/DHCP 86 Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 294 Index Notes: Rockwell Automation Publication 1756-UM535D-EN-P - November 2012...
Page 296 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products. At http://www.rockwellautomation.com/support, you can find technical manuals, technical and application notes, sample code and links to software service packs, and a MySupport feature that you can customize to make the best use of these tools.

This manual is also suitable for:

1756-rmxt 1756-rm2 1756-rm2xt

Allen-Bradley 1756-RM User Manual

Chapter 1 Enhanced Redundancy System Components

Chapter 2

Chapter 3 Enhanced Redundancy System Quick Start

Chapter 4 Requested Packet Interval

Configure the Ethernet/Ip Network

Chapter 5

Configure the Controlnet Network

Chapter 6

Configure the Redundancy Modules

Chapter 7

Program the Redundant Controller

Chapter 8

Monitor and Maintain an Enhanced Redundancy System

Chapter 9

Troubleshoot a Redundant System

Appendix A Redundancy Module Status Indicators

Appendix B before You Begin

Appendix D

Appendix E

Appendix F

Quick Links

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Allen-Bradley 1756-RM