1756-UM523A-EN-E, ControlLogix Redundancy System User Manual
Contents
1. 3 7 Replace Local I O Tags ware 3 8 Replace any Aliases to Local YO Tags 3 10 Tips for Configuring Your System nen ei 4 Reis 3 12 Chapter 4 When to Use this Chapter ses ur ar vee ee eR OKs 4 1 How to Use this Chapter se 24 ur i464 ag ing de Se beet 4 1 Download the Project to the Primary Controller 4 1 Select a Network Update Time 222222 4 3 Schedule the Netwotks pct Gane er ae 4 5 Schedule a New Network 222222222 4 5 Update the Schedule of an Existing Network 4 6 Test the Switchover teas Kniss Xe RN as 4 7 Publication 1756 UM523A EN E August 2001 Table of Contents ii Maintain and Troubleshoot the System Publication 1756 UM523A EN E August 2001 Adj st CNB Usage m Sana RE ade aes aG 4 9 Get the CPU Usage of a CNB Module 4 9 Reduce the CPU Usage of a CNB Module 4 11 Estimate the Switchover Time pugs fade we Pao a eee eed 4 11 Chapter 5 When to Use this Chapters ana Rea eR EKG 5 1 How to Use this Chapter 224 Verla para ets bad 5 1 Get System VAIS ae re 5 1 Send a Message to aModule 2222 5 5 Configure the 1757 SRM Module sn au ia 5 5 Enter the Message Instruction 2222222222 5 6 Configure the Message Instruction 5 7 Update a Keeper Signature us aie So Had ei es 5 10 Update Valid Keepers u a ren bet 5 10 Synchronize the Secondary Controller 5 11 pate 3 Module sans ans nah anne ec 52. more than one CNB module ina redundant the CNB modules are on the same network Use a NUT that is less than or equal to chassis 90 milliseconds the CNB modules are on different networks The NUT of each network must be within the values indicated in Table 4 1 If you use a larger NUT the controller could lose its connection with a module during a switchover This could cause outputs to change state Table 4 1 NUTs for multiple ControlNet networks Table 4 1 NUTs for multiple ControlNet networks Continued Ifthe smallest Then the largest NUT on anyother Ifthe smallest Then the largest NUT on any other NUT ona network network must be less than or equal NUT on a network network must be less than or equal is ms to ms is ms to ms FE 20 52 3 17 21 55 4 19 22 57 5 21 23 59 6 23 24 62 7 25 25 64 8 27 26 66 9 29 27 68 0 31 28 71 1 33 29 73 12 35 30 75 13 37 31 78 14 39 32 80 15 41 33 82 16 43 34 84 17 46 35 87 18 48 36 89 19 50 37 90 90 Publication 1756 UM523A EN E August 2001 4 4 Test and Tune the System EXAMPLE Network Update Times for Multiple ControlNet Networks If the NUT of this network is 5 ms Then the NUT of this network must be 21 ms or less _ LIC S C 5 N R N 5 B M B M x
3. 12 Publication 1756 UM523A EN E August 2001 42803 Choose Synchronize Secondary Choose Yes to confirm If the controller contains a large project the system may spend some time qualifying the secondary controller During this time the CNB module in the primary chassis will display PwQg In the primary chassis does the CNB module display PwOS If Then Yes The secondary controller is synchronized e In the 1757 SRM properties choose OK e Skip the remaining steps in this task No Go to step 11 Cycle power to the secondary chassis If the CNB module in the primary chassis fails to display PwQS contact your Rockwell Automation representative or local distributor Test and Tune the System 4 9 Adjust CNB Usage For each CNB module in a redundant chassis we recommend that you keep CPU usage to less than 75 percent e Each redundant CNB module needs enough additional processing time for redundancy operations e At peak operations such as qualification redundancy uses an additional 8 percent approximately of the CPU of the CNB module e A total CPU usage that is higher than 75 percent may prevent a secondary chassis from qualifying after a switchover To keep CPU usage of the CNB modules within the recommended limit e Get the CPU Usage of a CNB Module e Reduce the CPU Usage of a CNB Module Get the CPU Usage of a CNB Module To get the CPU usage of a CNB module you have these options
4. Allen Bradley ControlLogix Redundancy System User Manual Automation Important User Information Because of the variety of uses for the products described in this publication those responsible for the application and use of these products must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards In no event will Allen Bradley be responsible or liable for indirect or consequential damage resulting from the use or application of these products Any illustrations charts sample programs and layout examples shown in this publication are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Allen Bradley does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Allen Bradley publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Allen Bradley office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of this copyrighted publication in
5. Four Character Display e RSLinx Software e Message Instruction Four Character Display On the front of the 1756 CNB D or CNBR D module the four character display shows the CPU usage of the module The display shows the usage in this format YCKX where 42797 xx is the percent of CPU usage The range for the display is 00 99 Publication 1756 UM523A EN E August 2001 4 10 Test and Tune the System RSLinx Software 1 Start RSLinx software 2 Expand a network until you see your CNB module 3 Right click the module and choose Module Statistics 4 Click the Connection Manager tab number of connections used CPU usage 42903 Message Instruction See Send a Message to a Module on page 5 5 Publication 1756 UM523A EN E August 2001 Test and Tune the System 4 11 Estimate the Switchover Time For this type of failure Reduce the CPU Usage of a CNB Module To reduce the CPU usage of a module you have these options e Change the network update time NUT of the ControlNet network Typically increase the NUT to reduce the CPU usage of a CNB module Increase the requested packet interval RPD of your connections e Reduce the number of connections to through the CNB e Reduce the number of MSG instructions e Add another CNB module to each redundant chassis The switchover
6. 13 Disqualify the Secondary Chassis 5 13 Upgrade the Required Firmware of the Secondary Chassis 5 14 Make the Secondary Controller the New Primary Controller 5 15 Upgrade the Other Redundant Chassis 5 15 Change the Auto Synchronization Option to ALWAYS 5 16 Determine the Cause of a Switchover 5 17 When to Use this Chapter How to Use this Chapter Chapter 1 Design the System Use this chapter to design a redundancy system for a ControlLogix controller To design your system e Select the Hardware e Check Connection Requirements e Estimate Scan Time e Assign ControlNet Addresses e Develop the Bill of Materials If you are adding redundancy to an existing system also see the following section Tips for Adding Redundancy to an Existing System Publication 1756 UM523A EN E August 2001 1 2 Design the System Select the Hardware A ControlLogix redundancy system requires the following hardware 1756 L55M13 155M14 L55M16 155M23 or 155M24 controller e only 1 in each redundant chassis enough memory for 2 copies of all data m 1756 CNB D or CNBR D module or modules e 1 5 in each redundant chassis e Keep CPU usage lt 75 1757 SRM module redundant vi Beatin sed chassisa e only 1 in each redund
7. 16 1 Data 0 Replaced Rung 0 OTE Operand 0 OTE Local 2 0 Data 0 Replaced Rung 1 XIC Operand 0 XIC Local 16 1 Data 1 Replaced Rung 1 OTE Operand 0 OTE Local 2 0 Data 1 Replaced Rung 2 XIC Operand 0 XIC Local 16 1 Data 2 Replaced Rung 2 OTE Operand 0 OTE Local 2 0 Data 2 Replaced Rung 8 OTE Operand 0 OTE Local 15 0 CommandRegister Run Complete 7 occurrence s found 7 occurrence s replaced Publication 1756 UM523A EN E August 2001 3 10 Configure the System Replace any Aliases to Local 1 0 Tags Are any of your tags an alias for an I O device that was previously in a local chassis If Then Yes Go to step 1 No Skip this procedure 1 From the Zogic menu choose Edit Tags 2 Press the Ctrl H keys replace Replace in Tag Collections Ea 3 Find what x i aA Text Only 4 _ Replace with EA 5 Find Where Al Tags V Wrap Direction Match Whole Word Only C Up Down Find Within Tags 42815 3 Type Local 4 Type the name of the CNB module that is in the remote chassis 5 Select All Tags 6 Choose Find Within gt gt Publication 1756 UM523A EN E August 2001 Configure the System 3 11 Find Within T lt lt Find Within ags Components Options Alias lt Base Tag Description Name _ Type K 7 42815 7 Check Alias
8. O a A Network 1 Network 2 a Lic s c 5N R N 5 B M B M x O B aid m Pin i Publication 1756 UM523A EN E August 2001 Test and Tune the System 4 5 Schedule the Network Use the following procedures to schedule your network e Schedule a New Network Update the Schedule of an Existing Network Schedule a New Network In this box 1 Turn on the power to each chassis Start RSNetworx for ControlNet software From the File menu choose New From the Network menu choose Online Select your ControlNet network and choose OK Select the Edits Enabled check box From the Network menu choose Properties From the Network Parameters tab type or select the following parameters Specify Network Update Time repetitive time interval in which data is sent over the ControlNet network Max Scheduled Address greatest node number to use scheduled communications on the network Max Unscheduled Address greatest node number that you will use on the network Media Redundancy channels in use Network Name 10 11 12 13 14 name for the network choose OK From the Network menu choose Single Pass Browse From the File menu choose Save Type a name for the file that stores the network configuration then choose Save Select the Optimize and re write Schedule for all Connections button default and choose OK In RSLogix 5000 software sav
9. be required than if the same amount of data was spread across many individual tags To create arrays and user defined data types see the Logix5000 Controllers Common Procedures publication 1756 PM001 Publication 1756 UM523A EN E August 2001 1 6 Design the System Publication 1756 UM523A EN E August 2001 Execute Instructions Only When Required Anytime an instruction writes a value to a tag even if it is the same value the primary controller sends the value to the secondary controller Many instructions write a value to a tag whenever they are scanned e Instructions such as OTL OTU and many instructions with Destination operands write a value each time the rung condition in is true e Each execution of the instruction causes the primary controller to send additional data to the secondary controller even if the data did not change For example each time the controller executes an ADD instruction the controller must update the secondary controller This occurs even if the ADD instruction produced the same value as its previous execution To minimize scan time execute instructions only when required if possible This reduces the unnecessary update of data which reduces scan time Design the System 1 7 Assign ControlNet Addresses 1 Make sure that your network has at least 2 nodes in addition to IMPORTANT he the redundant chassis pair An additional node can be a e second CNB module in the same rem
10. identification of a specific chassis without regard to the state of the chassis If Then 0 unknown 1 Chassis A 2 Chassis B QualificationInProgress INT GSV status of the qualification process If Then 1 Qualification is not in progress 0 unsupported 1 99 For modules that can measure their completion percentage the percent of qualification that is complete 50 For modules that cannot measure their completion percentage qualification is in progress 100 Qualification is complete SRMSlotNumber INT GSV slot number of the 1757 SRM module in this chassis Publication 1756 UM523A EN E August 2001 5 4 Maintain and Troubleshoot the System Attribute Data Type Instruction Description LastDataTransferSize DINT GSV This attribute is only valid on a primary controller that is configured for redundancy If Then this value is the a synchronized partner is amount of data that was last present transferred to the partner specified in DINTs amount of data that would have been last transferred to a synchronized partner specified in DINTs no partner is present a disqualified partner is present MaxDataTransferSize DINT GSV Maximum value of the LastDataTransferSize attribute SSV e This attribute is only valid on a primary controller that is configured for redundancy e To reset this value use an SSV instruction with a Source value of 0 For more information on the status information that you can access with the
11. name 8b Instance name 1 Attribute name 1 Source WallClockTime 0 where WallClockTime isa DINT 2 array that stores the CurrentValue of the WALLCLOCKTIME object Num Of Elements 8 Destination leave blank get the CPU usage of a CNB module Message Type CIP Generic Service Code Af Class name al Instance name 8 Attribute name leave blank Publication 1756 UM523A EN E August 2001 Source tag that uses a user defined data type Members of the data type Tag value Name Data type offset DINT 0 size_returned INT 2 Num Of Elements 6 Destination INT tag in which to store the CPU usage of the CNB module 0 99 3 Click the Communication tab 4 In the Path box type the following path 1 slot_number where slot_number is the slot number of the module For a 1757 SRM module use the left hand slot number of the module 5 Choose OK Maintain and Troubleshoot the System 5 9 EXAMPLE Set the clock of the 1757 SRM module When set_time is on the GSV instruction gets the current value of the WALLCLOCKTIME object and stores the value in the WallClockTime array 64 bits The message instruction then sends the value to the SRM module set_time GSV Get System Value Class name WALLCLOCKTIME Instance name Attribute Name CurrentValue Dest WallClockTime 0 0 msg_set_time EN MSG Type CIP Generic Messa
12. of firmware Use the same revisions that you used for the first redundant chassis Publication 1756 UM523A EN E August 2001 3 2 Configure the System Synchronize the Controllers To synchronize the controllers in the redundant chassis pair e Select the Auto Synchronization Option e Synchronize the Controllers Select the Auto Synchronization Option 1 Go to RSLinx software To expand a network one level do one of Workstation the following e Double click the network Linx Gateways Ethernet e Select the network and press pe AB_KTC x ControlNet the key e Click the sign 2 Navigate to the CNB module of the primary chassis The primary chassis uses the node to which its rotary switches are set Workstation Linx Gateways Ethernet AB_KTC x ControlNet primary chassis gt xx 1756 CNB D 3 Expand the CNB module of the primary chassis 4 Expand the backplane Workstation Linx Gateways Ethernet AB_KTC x ControlNet xx 1756 CNB D Backplane 1756 Ax xx 1756 module 1757 SRM 5 Right click the 1757 SRM module and select Properties 6 Click the Configuration tab Publication 1756 UM523A EN E August 2001 Configure the System 3 3 1757 SRM REDUNDANCY MODULE
13. outstanding Overall Usefulness 1 2 3 How can we make this publication more useful for you c 1 2 3 Can we add more information to help you ompleteness all necessary information procedure step illustration feature ided is provided fe example guideline L other _ explanation _ definition Technical Accuracy 1 2 3 Can we be more accurate all provided information ae is correct L text L illustration Clarity 1 2 3 How can we make things clearer all provided information is easy to understand Other Comments You can add additional comments on the back of this form Your Name Location Phone Your Title Function Would you like us to contact you regarding your comments No there is no need to contact me Yes please call me Yes please email me at Yes please contact me via Return this form to Allen Bradley Marketing Communications 1 Allen Bradley Dr Mayfield Hts OH 44124 9705 Phone 440 646 3176 Fax 440 646 3525 Email RADocumentComments ra rockwell com Publication ICCG 5 21 January 2001 PN 955107 82 PLEASE FASTEN HERE DO NOT STAPLE Other Comments PLEASE FOLD HERE NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES BUSINESS REPLY MAIL FIRST CLASS MAIL PERMIT NO 18235 CLEVELAND OH POSTAGE WILL BE PAID BY THE ADDRESSEE Allen Bradley Fa a DOWSE 2 Rockwell A
14. state e Outputs in lower priority tasks may experience a change of state Who Should Use this This manual is intended for those individuals who design and develop Manual applications that use ControlLogix controllers such as e software engineers control engineers e application engineers e instrumentation technicians When to Use This Manual Use this manual throughout the life cycle of a redundancy system e design installation e configuration e testing e maintenance and troubleshooting Publication 1756 UM523A EN E August 2001 Preface 2 How to Use this Manual This manual is divided into the basic tasks that you perform during the design development and implementation of a ControlLogix redundancy system e Each chapter covers a task e The tasks are organized in the sequence that you will typically perform them As you use this manual you will see some text that is formatted differently from the rest of the text Text that is Identifies For example Means Italic the actual name of an item that you Right click User Defined Right click on the item that is named see on your screen or in an example User Defined courier information that you must supply Right click You must identify the specific program in based on your application a name_of_program your application Typically itisa name or variable variable that you have defined Publication 1756 UM523A EN E August 2001 Design the
15. steps to upgrade the revision of your redundant modules This procedure minimizes the time your process is down for the upgrade Mihara Do not connect your computer to the ControlNet network via the network access port on a CNB module in the primary chassis When you turn off power to the chassis you will lose access to the network To update a module e Disqualify the Secondary Chassis e Upgrade the Required Firmware of the Secondary Chassis e Make the Secondary Controller the New Primary Controller Upgrade the Other Redundant Chassis e Change the Auto Synchronization Option to ALWAYS Disqualify the Secondary Chassis 1 Start RSLinx software 2 Find the SRM module in the secondary chassis Workstation The secondary chassis is one node greater than the primary chassis Linx Gateways Ethernet AB_KTC x ControlNet xx 1756 CNB D xy 1756 CNB D Backplane 1756 Ax gt xx 1756 module 1757 SRM Publication 1756 UM523A EN E August 2001 5 14 Maintain and Troubleshoot the System 3 Right click the 1757 SRM module and select Properties 4 Click the Configuration tab 1757 SRM REDUNDANCY MODULE Module Inio Configuration Synchrenization Chassis Profile Event L Option 5 _ gt Auto Synchronization Option JaLways x Auto Sy Chassis Label Chassis B SRM Se ses
16. whole or part without written permission of Rockwell Automation is prohibited Throughout this publication notes may be used to make you aware of safety considerations The following annotations and their accompanying statements help you to identify a potential hazard avoid a potential hazard and recognize the consequences of a potential hazard Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices Or circumstances that can lead to personal injury or death property damage or economic loss IMPORTANT Identifies information that is critical for successful application and understanding of the product Allen Bradley is a trademark of Rockwell Automation Preface Purpose of this Manual This manual guides the design development and implementation of a redundancy system for a ControlLogix controller e Redundancy requires no additional programming and is transparent to any devices connected over the ControlNet network e When a failure occurs in any of the components in the primary chassis control switches to a controller in a secondary chassis e During the switchover outputs that are controlled by the highest priority task will experience a bump less switch over i e Outputs will not revert to a previous
17. 56 L55M113 L55M14 L55M16 L55M23 or L55M24 2 ControlNet bridge 1756 CNB D or CNBR D module 2 redundancy module 1757 SRM 1 fiber optic cable 1757 SRC1 SRC3 or SRC10 You also need the following materials The actual items depend on the design and lay out of your system Cat number as required for your I O modules Notes For ControlLogix chassis redundant power supplies are available as an option e For a redundant power supply kit order catalog number 1756 PAR or 1756 PBR e Each kit contains two redundant power supplies cable and adapter ControlNet adapters as required for your chassis or DIN rail e You need an adapter for each remote chassis or rail e If you are using a redundant ControlNet network order the redundant R version of each adapter e You need at least two ControlNet nodes in addition to the CNB modules in the redundant chassis pair ControlNet tap 1786 TPS TPR TPYS or TPYR If you are using a redundant ControlNet network you need two taps for each device on your ControlNet network RG 6 coaxial 1786 RG6 or RG6F cable terminator 1786 XT You need 2 terminators for each ControlNet segment RSLogix 5000 9324 RLD300 e Use revision 8 51 or later software RLD300NXENE or RSLinx Lit RLD700 e All three catalog numbers include RSLinx Lite software Use RSLinx MR revision 2 30 01 or later software e 9324 RLD300NXENE and RLD700 includ
18. 8 Choose Replace All 9 Choose Close Publication 1756 UM523A EN E August 2001 3 12 _ Configure the System Tips for Configuring Your e For any outputs that require a bumpless switchover System Put those outputs in the highest priority task Configure only that task at the highest priority Tatiana During a switchover the connection for tags that are consumed from a redundant controller may time out e The data does not update e The logic acts on the last data that it received After the switchover the connection reestablishes and the data begins to update again e If you want a controller in another chassis to consume a tag from the redundant controller use a comm form of None In the I O configuration of the consuming controller select a comm format of None for the remote CNB module the CNB that is physically in the redundant chassis produced tag To the controller with the consumed tag this is the remote CNB module redundant chassis vv LIC S T H 5N R 5B M M X i E wa N data consumed tag remote chassis wo x Foor In the I O configuration of this controller select a comm format of None for the remote CNB module Publication 1756 UM523A EN E August 2001 Configure the System 3 13 e For any MSG instruction from a controller in another chassis to a redundant controlle
19. DS use this table to troubleshoot the secondary chassis lf the SRM module And a secondary CNB And a secondary controller Then has a module has a Green OK LED does not display NET ERR Flashing Red OK LED Clear the major fault of the controller Solid Red OK LED 1 Cycle the power to the chassis 2 If the OK LED remains solid red replace the controller and flash the controller with the appropriate revision of firmware displays NET ERR Check all ControlNet taps connectors and he i i terminators for proper connections Red OK LED 1 Cycle the power to the chassis 2 If the CNB module in the primary gt chassis fails to display PwOS contact your Rockwell Automation representative or local distributor Publication 1756 UM523A EN E August 2001 5 18 Maintain and Troubleshoot the System Notes Publication 1756 UM523A EN E August 2001 How Are We Doing PANE Your comments on our technical publications will help us serve you better in the future Thank you for taking the time to provide us feedback Ty You can complete this form and mail it back to us visit us online at www ab com manuals or email us at RADocumentComments ra rockwell com Pub Title Type ControlLogix Redundancy System Cat No Pub No 1756 UM523A EN E Pub Date August 2001 Part No 957555 29 Please complete the sections below Where applicable rank the feature 1 needs improvement 2 satisfactory and 3
20. GSV instruction see Logix5000 Controllers General Instructions Reference Manual publication 1756 RM003 EXAMPLE Get system values The first GSV instruction gets the label of the chassis that is currently the primary chassis and stores the value in redundant_ID The second GSV instruction gets the redundancy state of the controller and stores the value in redundant_state GSV Get System Value Class name REDUNDANCY Instance name Attribute Name PhysicalChassisID Dest redundant_ID 16 0000_0000 Where Is redundant_ID GSV Get System Value Class name REDUNDANCY Instance name Attribute Name ModuleRedundancyState Dest redundant_state 16 0000_0000 Tag to store the chassis label The label tells you which chassis is acting as the primary chassis e Data type is DINT e Display style is Hex redundant_state Tag to store the value of the redundancy state of the controller e Data type is DINT e Display style is Hex Publication 1756 UM523A EN E August 2001 Maintain and Troubleshoot the System 5 5 Send a Message to a Module You can use ladder logic to perform the following actions e initiate a switchover e disqualify the secondary controller e synchronize the secondary controller e set the clock of the SRM module e get the CPU usage of a CNB module To send a message to a module e Configure the 1757 SRM Module e Enter the Message Instruction e Configure the Message Instruc
21. Module Inio Configuration Synchrenization Chassis Profile Event L Options 7 gt Auto Synchronization Option always x Auto Sy Chassis Label Chassis B 7 SRM Se 42802 7 Select ALWAYS 8 Choose OK Synchronize the Controllers 1 Turn on the chassis power to the partner secondary chassis 2 Wait for the 1757 SRM module to complete its power up cycle This may take one or two minutes 3 In the primary chassis does the CNB module display PwQS If Then yes The redundant chassis are synchronized Go to Configure the Project for the Controllers no The redundant chassis are not synchronized Go to step 4 U 42797 Publication 1756 UM523A EN E August 2001 3 4 Configure the System 4 In the secondary chassis what does the CNB module display If Then check the following Icpt A B C All CNB modules in each redundant chassis are series D modules Each CNB module has a partner in the same slot in the other redundant chassis Each pair of CNB modules one in each chassis is set to the same node address All CNB modules in each redundant chassis are valid keepers See Update a Keeper Signature on page 5 10 CMPT Each module has a partner in the same slot in the other redundant chassis Each pair of controllers one in each chassis h
22. System Install the System Configure the System Test and Tune the System Table of Contents Chapter 1 When to Use this Chapter 2 aio 2044253 Kies sl se 1 1 How to Use thissCha pier van ran Dean arts 1 1 Select the Hardware hans na aus U 1 2 Check Connection Requirements 2 2 2 22 1 3 Estimate Sean TIME meadi rer nee ie 13 Use Arrays and User Defined Data Types 1 5 Execute Instructions Only When Required 1 6 Assign ControlNet Addresses 0 0 0 0 00 0000000005 1 7 Develop the Bill of Materials 2222222 1 9 Tips for Adding Redundancy to an Existing System 1 10 Chapter 2 When to Use this Chapter rasanten 2 1 Before VOU Being fetter EGS 2 1 How to Use this Chapter ioe ne ee Pk Rey 2 3 Install the Chassis for the Controllers 2 3 Install Modules in the First Redundant Chassis 2 4 Install Modules in the Second Redundant Chassis 2 6 Install the Remote Chassis or Rails 2 22 2 2 7 Chapter 3 When to Use this Chapter ws a hassen a se ran a 3 1 How to Use this Chapter 5 0 0 u Hier aaa oe a 3 1 Hash tne Modules ie ia 3 1 Synchronize the Controllers 3 22 22 40 an ete ured 3 2 Select the Auto Synchronization Option 3 2 Synchronize the Controllers 2 2 222220 3 3 Configure the Project for the Controllers 3 5 Configure es Ate tg A Gece at hein Nicastro Be 3 7 Re Configure the Local YO Modules
23. VI Replace Local I O Tags 1 Open a routine If a routine is already open click within the routine to activate the window 2 Press the Ctrl H keys replace Replace in Routines x 3 Find what za v Ema tert Text Only 4 _ Replace with x ES 5 Find Where la II Routines El Frag a Replace All Close V Wrap Direction elp I Match Whole Word Only C Up Down Find Within Function Block Diagrams Ladder Diagrams Find Within gt e 42804 3 Type Local 4 Type the name of the CNB module that is in the remote chassis 5 Select All Routines 6 Choose Find Within gt gt Publication 1756 UM523A EN E August 2001 Configure the System 3 9 Find Within Function Block Diagrams Ladder Diagrams lt lt Find Within Components Options Function Block Diagrams Instruction Main Operand Comments Ladder Diagrams Instruction Operands gq Instructions Rung Comments Rung Types lt q 4 42805 8 7 Select Ladder Diagram 8 Check Instruction Operands 9 Choose Replace All The Search Results tab displays the changes to the logic 10 Choose Close The following example shows the results of replacing Local with chassis_c Replacing Local with chassis_c Searching through MainProgram MainRoutine Replaced Rung 0 XIC Operand 0 XIC Local
24. ant chassis vv e uses 2 slots LIC S 5 R no other lt 518 M modules M x 5 to SRM module it A 1757 SRCx cable in chassis b identical modules ControlNet network i samesatnimber e Set NUT lt 90 ms e same catalog number series and revision same size of chassis lt e Set APIs lt 375 ms e same memory size controller redundant chassis b Y LIC S 51N R no other lt 5 B M modules M x ji Ot 1 0 chassis Remote location for all C Elo po m Assign the lowest node gt S N 1 0 modules n nlalv e 1 0 ue to the remote B B By Ry 1 e non CNB communication casals AA l modules pide 0 b III 0 at least 2 nodes in other networks addition to the redundant chassis pair An additional node can be a e second CNB module in the same remote chassis or in a different remote chassis H e any other ControlNet device e workstation that is running RSLinx software Publication 1756 UM523A EN E August 2001 Design the System 1 3 Check Connection Make sure that each controller and CNB module in a redundant chassis has available enough connections for redundancy Requirements communications Redundancy communications require the following number of additional connections This module Uses this many additional Description connections for redundancy controller 7 2 for the SRM 5 for the partner CNB 3 2 for the SRM 1 for the partner Estimate Scan Time After each scan of the logic the prim
25. ary controller sends to the secondary controller the result of any output instruction that executed during the scan scan time update secondary execute logic controller This increases the scan time of a project when compared to a non redundant system e The amount of increase depends on how much data must be sent to the secondary controller e Figure 1 1 on page 1 4 compares the scan times for redundant and non redundant controllers Publication 1756 UM523A EN E August 2001 1 4 Design the System Figure 1 1 The following graph shows the scan time verses data transfer for redundant and non redundant projects The curves represent projects with small medium and large scan times 300 250 200 redundant 150 undant maximum scan time non redunda 100 non redunda 50 non redundant 0 3072 7168 11264 15360 19456 23552 27648 31744 35840 39936 44032 48128 amount of data that is sent to the secondary controller per scan specified in DINTs Publication 1756 UM523A EN E August 2001 For this information Design the System 1 5 To determine the amount of data that transfers to the secondary controller during a scan use a GSV instruction to access the REDUNDANCY object only available for a controller that is configured f
26. as the same memory board e g 1756 L55M14 C Each module contains compatible firmware DUPL NODE B No other device on the ControlNet network is set to the address of the CNB modules plus one For example if the CNB modules are set to 3 no other device should be set to 4 The 1756 SRCx cable is connected to both SRM modules NET ERR All ControlNet taps connectors and terminators are connected 5 Go to step 3 Publication 1756 UM523A EN E August 2001 Configure the System 3 5 Configure the Project for In this step you configure the project for your controller the Controllers m 1 Open or create the RSLogix 5000 project Offline J F RUN el No Forces gt M OK a F BAT No Edits m 1 0 Redundancy 59 42627 2 On the Online toolbar click the controller button 3 Does the General tab show that the controller type is a 1756 L55 controller If Then No A Click the Change Type button B Select a 1756 L55 controller C Choose OK Yes Go to step 4 4 Click the Redundancy tab General Serial Port System Protocol User Protocol Maior Faults Minor Faults Date Time Advanced File Redundancy 5 I Redundancy Enabled Advanced 42624 5 Select the Redundancy Enabled check box General Serial Port System Protocol User Protocol Maior Faults Minor Faults Date Time Advanced File Redundancy M Redundancy Ena
27. aults 10 To start control of the process from the Communications menu choose Run Mode Upgrade the Other Redundant Chassis 1 Turn on power to the other redundant chassis 2 Upgrade the required firmware of the chassis Publication 1756 UM523A EN E August 2001 5 16 Maintain and Troubleshoot the System Change the Auto Synchronization Option to ALWAYS 1 Go to RSLinx software 2 Find the SRM module in the primary chassis and open the properties of the module 3 On the Configuration tab change the Auto Synchronization Option to ALWAYS 4 Choose OK Publication 1756 UM523A EN E August 2001 Maintain and Troubleshoot the System 5 17 Determine the Cause ofa If an unplanned switchover occurs use the following tables to Switchover determine the cause of the switchover In the primary chassis what does the CNB module display If Then PwNS Go to Table 5 2 PwDS Go to Table 5 3 Table 5 2 If a CNB module displays PWNS use this table to troubleshoot the secondary chassis If the secondary chassis And each primary CNB And a secondary CNB Then module module has a has power has a partner module in the Red OK LED Replace the CNB module Seuolanfchassis Green OK LED Check the 1756 SRC cable for a proper connection does not have a partner module Install a CNB module in the secondary chassis does not have power p Restore the power Table 5 3 If a CNB module displays Pw
28. bled 42626 6 Click the Advanced button Publication 1756 UM523A EN E August 2001 3 6 Configure the System Advanced Redundancy Configuration Memory Usage Indicate whether more of the processor memory that is free after download is to be reserved for online creation of tags or logic Reserve more memory for online addition of I Logic Cancel Help 42625 7 We recommend that you leave this check box cleared unchecked This prevents an incorrect online edit from faulting both the primary and secondary controller If you want any test edits to remain active during a switchover at the risk of faulting both controllers then check this check box 8 For online editing how to you want to reserve any free memory If Then equally between data and logic Leave the default setting more for data and less for logic Drag to slider toward Tags less for data and more for logic Drag to slider toward Logic 9 Choose OK 10 To close the Controller Properties dialog box choose OK Publication 1756 UM523A EN E August 2001 Configure the System 3 7 Configure 1 0 In this step you configure the communications between the controller and its I O modules IT For each module in your system make sure that the requested packet interval RPD is less than or equal to 375 milliseconds If you use a larger RPI the controller could lose its connection with the module
29. cation 1756 IN571 WARNING If you connect or disconnect the ControlNet cable with power applied to this module or any device on the network an electrical arc can occur This could cause an explosion in hazardous location installations Be sure that power is removed or the area is nonhazardous before proceeding 3 Connect the CNB module to the ControlNet network Publication 1756 UM523A EN E August 2001 lt 5 1 07 on ee de Install the System 2 5 This is only an example You can install the modules in any slot 42799 4 Install the 1756 L55Mxx controller See ControlLogix Controller and Memory Board Installation Instructions publication 1756 IN101 5 Install the 1757 SRM module See ProcessLogix ControlLogix System Redundancy Module Installation Instructions publication 1757 IN092 Publication 1756 UM523A EN E August 2001 2 6 Install the System Install Modules in the Second Redundant Chassis LIC S LIC S m 5 N R 5 N R 5 B M 5 B M wy 2 _ VY 42800 3 IMPORTANT e The modules in each redundant chassis must match each other slot by slot e Set the rotary switches of the 1756 CNB D or CNBR D modules for both redundant chass
30. during a switchover This could cause outputs to change state Determine where to start If you are And the system Then converting an existing system to contained only remote I O modules You do not have to change the I O configuration of the a redundant system controller Go to Test and Tune the System on page 4 1 contained local 1 0 modules Use the procedures in this section to convert the configuration of local modules to remote modules e Re Configure the Local 1 0 Modules e Replace Local I O Tags e Replace any Aliases to Local 1 0 Tags configuring a new system for gt Configure the I 0 See the ControlLogix System User redundancy Manual publication 1756 UM001 Re Configure the Local 1 0 Modules 1 If you have not already done so add the CNB module of the remote chassis to the I O configuration of the controller See the ControlLogix System User Manual publication 1756 UM001 1 0 Configuration x 1756 xxx name_of_local_module lt q Cut local 1 0 modules from here x 1756 CNB x name_of_local_CNB z x 1756 CNB x name_of_remote_CNB q Paste the I O modules here 2 In the controller organizer cut the modules from the local I O configuration and paste them into the remote CNB module Cut and paste the following modules e I O e 1756 DHRIO Publication 1756 UM523A EN E August 2001 3 8 Configure the System e 1756 DNB e 1756 ENET or ENB e 1756 M
31. e RSNetworx for ControlNet software e 9324 RLD700 lets you program in both ladder instructions and function blocks RSNetWorx for 9357 CNETL3 revision 3 00 ControlNet Publication 1756 UM523A EN E August 2001 1 10 Design the System Tips for Adding Redundancy to an Existing System Publication 1756 UM523A EN E August 2001 If you are adding redundancy to an existing system follow these suggestions e If you change the node number of a CNB module you may affect messages tags or listen only connections in other devices Choose node numbers that have the least impact on existing communications e If your existing system contains local I O modules you still need two additional chassis A redundant system can use only I O that is in a remote chassis i e not in the same chassis as the controller Refer to Install the Remote Chassis or Rails on page 2 7 We recommend that you move the existing 1756 L55Mxx controller from the original chassis and place it in a redundant chassis When to Use this Chapter Before You Begin Chapter 2 Install the System Use this chapter to install the hardware of your ControlLogix redundancy system This chapter provides the sequence of tasks and the critical actions for the successful installation of your ControlLogix redundancy system It does not replace the installation instructions for the components of the system e In addition to this manual use the foll
32. e the online project Publication 1756 UM523A EN E August 2001 4 6 Test and Tune the System In this box Update the Schedule of an Existing Network 1 Turn on the power to each chassis Start RSNetworx for ControlNet software From the File menu choose Open Select the file for the network and choose Open From the Network menu choose Online Select the Edits Enabled check box From the Network menu choose Properties From the Network Parameters tab update the following parameters Specify Max Scheduled Address greatest node number to use scheduled communications on the network Max Unscheduled Address Publication 1756 UM523A EN E August 2001 10 11 12 13 greatest node number that you will use on the network choose OK From the Network menu choose Single Pass Browse From the File menu choose Save Select the Optimize and re write Schedule for all Connections button default and choose OK In RSLogix 5000 software save the online project Test and Tune the System 4 7 Test the Switchover 1 Display RSLinx software 2 Expand the network until you see the 1757 SRM module in the primary chassis Workstation Linx Gateways Ethernet AB_KTC x ControlNet xx 1756 CNB D Backplane 1756 Ax xx 1756 module 1757 SRM 3 Right click the 1757 SRM
33. epeat steps 4 and 5 for each redundant CNB module that is not a valid keeper 7 Choose Close Synchronize the Secondary Controller 1 Go to RSLinx software 2 Expand the network until you see the 1757 SRM module in the primary chassis Workstation Linx Gateways Ethernet AB_KTC x ControlNet xx 1756 CNB D Backplane 1756 Ax x 1756 module 1757 SRM 3 Right click the 1757 SRM module and select Properties Publication 1756 UM523A EN E August 2001 5 12 Maintain and Troubleshoot the System 4 Click the Synchronization tab 1757 SRM REDUNDANCY MODULE Module Inio Configuration Synchrenization Chassis Profile Event Log Commands Synchronize Secondary Disqualify Secondary Initiate Switchover Become Primary 4 42803 5 5 Choose Synchronize Secondary 6 Choose Yes to confirm 7 Choose OK Primary 8 In the primary chassis what does the CNB module display If Then PwQS The controller is synchronized PwDS The secondary controller is not synchronized Go to Synchronize the Controllers step 4 on page 3 4 42797 Publication 1756 UM523A EN E August 2001 Maintain and Troubleshoot the System 5 13 Update a Module Use the following
34. essemesssssnsenssensssssomessnssssncensenssnssmesseossnssnsesey A Le dia 42802 5 Select NEVER 6 Choose Apply 7 Click the Synchronization tab 1757 SRM REDUNDANCY MODULE Module Inio Configuration Synchrcnization Chassis Profile Event Log Commands Synchronize Secondery Disqualify Secondary Initiate Switchover Become Primary t 42803 8 Choose Disqualify Secondary 9 Choose Yes to confirm Upgrade the Required Firmware of the Secondary Chassis See theControlLogix Controller and Memory Board Installation Instructions publication 1756 IN101 Publication 1756 UM523A EN E August 2001 Maintain and Troubleshoot the System 5 15 Make the Secondary Controller the New Primary Controller 1 Start RSLogix 5000 software 2 Download the project to the secondary controller 3 When it is safe to stop the control of your system change the primary controller to Program Mode 4 Turn off power to the primary chassis 5 Go to the 1757 SRM properties of the secondary chassis Commands SUACHTGni2e Secondary Initiate SiwiteHeyver Disgualiy Secondary Become Primary N 42808 7 In RSLogix 5000 software go online to the new primary controller 6 Choose Become Primary 8 The controller is faulted When a disqualified secondary controller becomes a primary controller the controller experiences a major fault 9 From the Communications menu choose Clear F
35. figured CEND e Message Control message lt DND e ER gt e 42424 5 Enter message EN where message is the message control tag from step 3 Publication 1756 UM523A EN E August 2001 Maintain and Troubleshoot the System 5 7 Configure the Message Instruction 1 In the MSG instruction click 2 Select a configuration for the message Table 5 1 Message to a Module If you want to For this item Type or select initiate a switchover Message Type CIP Generic Service Code 4e Class name bf Instance name 1 Attribute name leave blank Source DINT tag with a value of 1 Num Of Elements 4 Destination leave blank disqualify the secondary controller Message Type CIP Generic Service Code 4d Class name bf Instance name 1 Attribute name leave blank Source DINT tag with a value of 1 Num Of Elements 4 Destination leave blank synchronize the secondary controller Message Type CIP Generic Service Code 4c Class name bf Instance name 1 Attribute name leave blank Source DINT tag with a value of 1 Num Of Elements 4 Destination leave blank Publication 1756 UM523A EN E August 2001 5 8 Maintain and Troubleshoot the System Table 5 1 Message to a Module Continued If you want to set the clock of the SRM module For this item Type or select Message Type CIP Generic Service Code 10 Class
36. ge Control msg_set_time E YY 42807 Publication 1756 UM523A EN E August 2001 5 10 Maintain and Troubleshoot the System Update a Keeper Signature Secondary 42797 If the secondary chassis fails to qualify and its CNB module displays cpt the keeper signature of a CNB module may not match its partner This occurs if you schedule the ControlNet network while the secondary chassis is off or if the CNB module was previously configured in a different network To update a keeper signature Update Valid Keepers e Synchronize the Secondary Controller Update Valid Keepers 1 Start RSNetWorx for ControlNet software 2 Has this network been scheduled before If Then No A From the File menu select New B From the Network menu select Online C Select your ControlNet network and choose OK Yes A From the File menu select Open B Select the file for the network and choose Open C From the Network menu select Online 3 From the Network menu choose Keeper Status Publication 1756 UM523A EN E August 2001 Maintain and Troubleshoot the System 5 11 Y Keeper Capable Node Active Keeper Valid Keeper offline file N A N A 01 NO NO 02 YES YES 4 In the Valid Keeper column find a redundant node whose status is NO 5 Select the node and choose Update Keeper 6 R
37. is to the same node address 1 For each module in the first redundant chassis install an identical module into the same slot of the second redundant chassis 2 Connect the CNB module s to the ControlNet network 3 Connect the 1757 SRC1 SRC3 or SRC10 fiber optic cable to the 1757 SRM modules Publication 1756 UM523A EN E August 2001 Install the System 2 7 Install the Remote Chassis You must install all O modules and additional types of communication modules in remote chassis or on DIN rails The or Rails following example shows a remote 1756 chassis You can use any type of chassis or device that you can connect to the ControlNet network EtherNet IP network L jc s Ehe 3S Pasty C E 5 IN R 5 IN R N 1 0 modules N 5 B M 5 B M B B 42197 other ControlNet node s You must have at least one other node in addition to the redundant chassis pair and the remote I O chassis See Select the Hardware on page 1 2 IMPORTANT If you connect the workstation to the network via a network access port on a CNB module use a CNB module in a remote chassis This lets the workstation stay online with the new primary controller after a switchover As you install the chassis follow these guidelines e Do not assign any device to the addre
38. module and select Properties 4 Click the Synchronization tab 1757 SRM REDUNDANCY MODULE Module In o Configuration Synchrenization Chassis Profile Event Log Commands Synchronize Secondary Disqualify Secondar Initiate Switchover Become Eimer 42803 5 Choose Initiate Switchover 6 Choose Yes to confirm the switchover The CNB module s in the new primary chassis display a sequence of status messages Typically the module s displays the following sequence PwNS gt PwDS gt PwQg gt PwQs primary with primary with primary with primary with no secondary disqualified qualifying qualified secondary secondary secondary Publication 1756 UM523A EN E August 2001 4 8 Test and Tune the System 7 In the primary chassis what does the CNB module display If Then PwQS The switchover was successful and the redundancy system functions correctly e In the 1757 SRM properties choose OK e Skip the remaining steps in this task PwDS The switchover occurred but the secondary controller s did not synchronize Go to step 8 1757 SRM REDUNDANCY MODULE TO i Module Inio Configuration Synchrcnization Chassis Profile Event Log T Commands Synchronize Secondery Disqualify Secondary Initiate Switchover Become Eimer 4 8 10 11
39. network and press tg AB_KTC x ControlNet the key e Click the sign 3 Navigate to the CNB module of the primary chassis The primary chassis uses the node to which its rotary switches are set Workstation Linx Gateways Ethernet AB_KTC x ControlNet primary chassis u xx 1756 CNB D secondary chassis gt F xy 1756 CNB D 4 Expand the CNB module of the primary chassis Publication 1756 UM523A EN E August 2001 4 2 Test and Tune the System 5 Expand the backplane Workstation Linx Gateways Ethernet AB_KTC x ControlNet xx 1756 CNB D Backplane 1756 Ax xx 1756 L55Mxx 6 Select the controller and choose Download A confirmation box opens 7 Choose Download You do not have to download the project to the secondary controller When the secondary controller is synchronized the system automatically transfers the project to the secondary controller Publication 1756 UM523A EN E August 2001 Test and Tune the System 4 3 Select a Network Update Use a network update time NUT that is less than or equal to the Time following values If you have And Then only one CNB module in a redundant chassis Use a NUT that is less than or equal to 90 milliseconds gt
40. ondary chassis will automatically use the primary CNB module s address plus one On switchover the primary and secondary CNB modules swap addresses Do not configure any other device on the ControlNet network for either of these addresses For example if you allocated nodes 3 and 4 for the redundant chassis then no other device should use those node numbers If each redundant chassis has multiple CNB modules assign a pair of node numbers for each pair of CNB modules one in each chassis Use the following worksheet to record the slot number and node numbers for each pair of CNB modules Table 1 1 Slot and node numbers for 1756 CNB D or CNBR D modules redundant chassis 1st pair of CNB modules Pair of CNB modules one in each Slot and node numbers Slot Primary node Secondary node primary node 1 2nd pair of CNB modules 3rd pair of CNB modules Ath pair of CNB modules Publication 1756 UM523A EN E August 2001 5th pair of CNB modules Design the System 1 9 Develop the Bill of Materials Table 1 3 Additional Materials v Oty Item chassis or DIN rails The ControlLogix redundancy system requires the following hardware for your controllers Table 1 2 Bill of Materials for the Redundant Controller Chassis Y Oty Item Cat number 2 chassis 1756 A4 A7 A10 A13 or A17 2 power supply 1756 PA72 PB72 PA75 or PB75 2 controller 17
41. or redundancy Get this attribute Number of DINTs that were or would have been transferred LastDataTransferSize If Then this value is the a synchronized partner is present amount of data that was last transferred to the partner specified in DINTs no partner is present amount of data that would have been last transferred to a a disqualified partner is present synchronized partner specified in DINTs Maximum value of the LastDataTransferSize attribute MaxDataTransferSize For more information on using the GSV instruction see Get System Values on page 5 1 To minimize the scan time of your project e Use Arrays and User Defined Data Types e Execute Instructions Only When Required Use Arrays and User Defined Data Types To update the secondary controller the primary controller divides its memory into blocks of 256 bytes Anytime an instruction writes a value the primary controller sends the entire block that contained the value to the secondary controller To minimize scan time organize your data into arrays and user defined data types structures whenever possible Arrays and structures provide these advantages Data is more compact This lets the primary controller send it more quickly to the secondary controller e Related data is grouped together Related data is likely to change at the same time Since the controller sends data in 256 byte blocks fewer blocks may
42. osion in hazardous location installations Be sure that power is removed or the area is nonhazardous before proceeding Repeated electrical arcing causes excessive wear to contacts on both a module and its mating connector Worn contacts may create electrical resistance that can affect module operation Maaniie Preventing Electrostatic Discharge This equipment is sensitive to electrostatic discharge which can cause internal damage and affect normal operation Follow these guidelines when you handle this equipment e Touch a grounded object to discharge potential Static e Wear an approved grounding wriststrap e Do not touch connectors or pins on component boards e Do not touch circuit components inside the equipment e If available use a static safe workstation e When not in use store the equipment in appropriate static safe packaging Install the System 2 3 How to Use this Chapter To install the system e Install the Chassis for the Controllers e Install Modules in the First Redundant Chassis e Install Modules in the Second Redundant Chassis e Install the Remote Chassis or Rails Install the Chassis for the Controllers 42798 1 Install the two ControlLogix chassis that will contain the controllers i e the redundant chassis e Place the chassis within the length of your 1757 SRCx cable e Install each chassis acco
43. ote chassis or in a different remote chassis e any other ControlNet device e workstation that is running RSLinx software If your ControlNet network contains only one node other than the redundant chassis pair that node will drop its connections during a switchover This may cause the outputs of that node to change state during the switchover MIT 2 Assign the lowest ControlNet addresses to I O chassis and other remotely located chassis I e Do not assign the lowest addresses to the redundant chassis pair If you assign the lowest address to a CNB module in the redundant chassis pair e On a switchover you may temporarily lose communication with I O modules produced tags and consumed tags e If you remove the CNB module from the primary chassis while chassis power is on you may temporarily lose communication with I O modules produced tags and consumed tags e If every ControlNet node powers down at the same time e g a plant wide power loss you may have to cycle the power to the primary chassis to restore communication Publication 1756 UM523A EN E August 2001 1 8 Design the System 3 Allocate two consecutive ControlNet addresses for the pair of redundant chassis e g nodes 3 and 4 Use Table 1 1 on page 1 8 to record your network addresses The 1756 CNB D or CNBR D modules in the pair of redundant chassis share two ControlNet addresses The matching 1756 CNB D or CNBR D module in the sec
44. owing installation instructions as you install your system Install this component According to this publication 1756 A4 A7 A10 A13 or A17 ControlLogix Chassis Installation Instructions chassis publication 1756 INO80 1756 PA72 or PB72 power supply ControlLogix Power Supplies Installation Instructions publication 1756 5 67 1756 PA75 or PB75 power supply ControlLogix Power Supplies Installation Instructions publication 1756 5 78 1756 155M13 L55M14 or L55M16 ControlLogix Controller and Memory Board controller Installation Instructions publication 1756 IN101 1756 CNB D or CNBR D module ControlLogix ControlNet Bridge Installation Instructions publication 1756 IN571 1757 SRM module ProcessLogix ControlLogix System Redundancy Module Installation Instructions publication 1757 IN092 e The installation instructions for each component provide the following information which is required for your system detailed installation steps safety considerations enclosure requirements specifications hazardous location information Publication 1756 UM523A EN E August 2001 2 2 Install the System Publication 1756 UM523A EN E August 2001 Before you install the system review the following guidelines for safe handling of ControlLogix components WARNING When you insert or remove a module while backplane power is on an electrical arc can occur This could cause an expl
45. r cache the connection Properties of the Message to the Redundant Controller Message Configuration Message_1 Configuration Communication Tag Path Redundant_Controller 4 path to the redundant controller Redundant_Controller sommunication Method DET DHF Eranme Destination Lint 5 C IE hth Source Lint Destination lode SoufGe IV Cache Connections e 42977 t Leave this box checked e If you plan to monitor tags directly in the secondary controller not typical monitor from no more than 3 devices through a CNB module Publication 1756 UM523A EN E August 2001 3 14 Configure the System Notes Publication 1756 UM523A EN E August 2001 Chapter 4 Test and Tune the System When to Use this Chapter After you configure your system use this chapter to make sure that your system switches control as required How to Use this Chapter To test and tune the system e Download the Project to the Primary Controller Select a Network Update Time e Schedule the Network e Test the Switchover e Adjust CNB Usage e Estimate the Switchover Time Download the Project to the 1 In RSLogix 5000 software from the File menu choose Save Primary Controller 2 From the Communications menu choose Who Active To expand a network one level do one of Workstation the following e Double click the network Linx Gateways Ethernet e Select the
46. rding to the ControlLogix Chassis Installation Instructions publication 1756 IN080 e If you are converting an existing system that contains local I O modules you still need two additional chassis A redundant system can use only remote I O 2 For each chassis install a ControlLogix power supply according to the corresponding installation instructions Install this power supply According to this publication 1756 PA72 ControlLogix Power Supplies Installation 1756 PB72 Instructions publication 1756 5 67 1756 PA75 ControlLogix Power Supplies Installation 1756 PB75 Instructions publication 1756 5 78 Publication 1756 UM523A EN E August 2001 2 4 Install the System Install Modules in the First Redundant Chassis Set the rotary switches of the 1756 CNB D or IMPORTANT IMPORTANT CNBR D modules for both redundant chassis to the same node address 1 Set the rotary switches of each of the 1756 CNB D or CNBR D modules to the primary node number from Table 1 1 on page 1 8 123 123 o o m 42796 For example if you allocated nodes 3 and 4 for the redundant chassis set both CNB modules to node 3 2 This is only an example You can install the module in any slot c N B 42798 2 Install a 1756 CNB D or CNBR D module See ControlLogix ControlNet Bridge Installation Instructions publi
47. ry 16 3 primary with disqualified secondary 16 4 primary with no secondary 16 6 primary with qualifying secondary PartnerChassisRedundancy INT GSV redundancy state of the partner chassis er If Then 16 8 qualified secondary 16 9 disqualified secondary with primary PartnerKeyswitch DINT GSV position of the keyswitch of the partner If Then the keyswitch is in 0 unknown 1 RUN 2 PROG 3 REM PartnerMinorFaults DINT GSV status of the minor faults of the partner if the ModuleRedundancyState Publication 1756 UM523A EN E August 2001 indicates that a partner is present This bit Means this minor fault 4 problem with an instruction program 6 periodic task overlap watchdog 9 problem with the serial port 10 low battery Maintain and Troubleshoot the System 5 3 Attribute Data Type Instruction Description PartnerMode DINT GSV mode of the partner If Then 16 0 power up 16 1 program 16 2 run 16 3 test 16 4 faulted 16 5 run to program 16 6 test to program 16 7 program to run 16 8 test to run 16 9 run to test 16 A program to test 16 B into faulted 16 C faulted to program PartnerModuleRedundancy INT GSV redundancy state of the partner state If Then 16 7 qualifying secondary 16 8 qualified secondary 16 9 disqualified secondary with primary PhysicalChassisID INT GSV In a pair of redundant chassis
48. ss of the CNB modules in the redundant chassis plus one For example if you set the rotary switches of the CNB modules in the redundant chassis to node 1 no other device should use node 2 e Use a remote chassis for communication modules such as 1756 ENET or ENB 1756 DHRIO 1756 MVI 1756 DNB Publication 1756 UM523A EN E August 2001 2 8 Install the System Notes Publication 1756 UM523A EN E August 2001 When to Use this Chapter How to Use this Chapter Flash the Modules Redundancy Module 42801 Chapter 3 Configure the System After you have installed your system use this chapter to configure the system for redundancy To configure the system e Flash the Modules e Synchronize the Controllers e Configure the Project for the Controllers e Configure I O e Tips for Configuring Your System 1 Turn on the power to one of the redundant chassis 2 Wait for the 1757 SRM module to display PRIM 3 Flash upgrade each module in the chassis with a compatible revision of firmware See the ControlFLASH Firmware Upgrade Kit User Manual publication 1756 6 5 6 e To find the chassis in RSLinx software use the node number that the CNB module in the chassis displays 4 Turn off the power to the chassis 5 Turn on the power to the second redundant chassis 6 Wait for the 1757 SRM module to display PRIM 7 Flash upgrade each module in the chassis with a compatible revision
49. time of a redundant system depends on the network update time NUT of the ControlNet network To estimate the switchover time use the following formulas The switchover time is Example 5 NUT MAX 2 NUT 30 For a NUT of 10 ms the switchover time is loss of power module fails approximately 80 ms CNB module cannot communicate with any other node 14 NUT MAX 2 NUT 30 50 For a NUT of 10 ms the switchover time is approximately 220 ms where NUT is the network update time of the network Publication 1756 UM523A EN E August 2001 4 12 Test and Tune the System Notes Publication 1756 UM523A EN E August 2001 When to Use this Chapter Chapter 5 Maintain and Troubleshoot the System This chapter provides a variety of procedures to assist as you commission and operate your redundancy system How to Use this Chapter If you want to use ladder logic to get system or status information about your redundancy system Then see this section Get System Values Which starts on page 5 1 use ladder logic to initiate a redundancy action such Send a Message to a Module 5 5 as synchronize the secondary controller update the keeper signature of a CNB module because either e The module was off when you scheduled the network e The module was previously used in a different system Update a Keeper Signature 5 10 change the revision of a module while minimi
50. tion Configure the 1757 SRM Module To send a message to an 1757 SRM module configure the module to respond to ladder logic messages 1 Start RSLinx software 2 Expand the network until you see the SRM module in the primary chassis Workstation Linx Gateways Ethernet AB_KTC x ControlNet xx 1756 CNB D Backplane 1756 Ax xx 1756 module 1757 SRM 3 Right click the 1757 SRM module and select Properties 4 Click the Configuration tab Publication 1756 UM523A EN E August 2001 5 6 Maintain and Troubleshoot the System 1757 SRM REDUNDANCY MODULE Module Ino Configuration Synchrenization Chassis Profile Event L Option Auto Synchronization Option JaLways bed Auto Sy Chassis Label Chassis B 7 SRM Se 42802 5 Select the Enable User Program Control check box This is the default setting 6 Choose OK Enter the Message Instruction 1 Open the RSLogix 5000 project 2 Enter a MSG instruction and associated input instruction s e condition MSG e J E 4 E Message CEN gt e Message Control m lt DND e A IERD e o 42424 3 In the MSG instruction type a name for the message control tag and press the Enter key 4 In the MSG instruction right click the message control tag and select New tag_name e condition 4 5 MSG e IF 4 E Type Uncon
51. utomation 1 ALLEN BRADLEY DR MAYFIELD HEIGHTS OH 44124 9705 PLEASE REMOVE Reach us now at www rockwellautomation com Wherever you need us Rockwell Automation brings together leading brands in industrial automation including Allen Bradley controls Reliance Electric power transmission products Dodge mechanical power transmission components and Rockwell Software Rockwell Automation s unique flexible approach to helping customers achieve a competitive advantage is supported by thousands of authorized partners distributors and system integrators around the world Allen Bradley Eiern Does E ROCKWELL Rockwell SOFTWARE Americas Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 European Headquarters SA NV avenue Herrmann Debroux 46 1160 Brussels Belgium Tel 32 2 663 06 00 Fax 32 2 663 06 40 Asia Pacific Headquarters 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Automation Publication 1756 UM523A EN E August 2001 PN 957555 29 2001 Rockwell International Corporation Printed in the U S A
52. zing the Update a Module 5 13 time your system is off diagnose the cause of an unplanned switchover Determine the Cause of a 5 17 Switchover Get System Values You can use a GSV instruction in your ladder logic to get system values for your redundancy system You can then display that information on an HMI screen The REDUNDANCY object provides the following status information about the redundancy system Attribute Data Type Instruction Description ChassisRedundancyState INT GSV redundancy status of the entire chassis If Then 16 1 power up or undetermined 16 2 primary with qualified secondary 16 3 primary with disqualified secondary 16 4 primary with no secondary Publication 1756 UM523A EN E August 2001 5 2 Maintain and Troubleshoot the System Attribute Data Type Instruction Description CompatibilityResults INT GSV results of the compatibility checks with the partner controller If Then 0 undetermined 1 no compatible partner 2 fully compatible partner KeyswitchAlarm DINT GSV keyswitch settings of the controller and its partner match or do not match If Then 0 one of the following e The keyswitches match e No partner is present 1 keyswitches do not match ModuleRedundancyState INT GSV redundancy status of the controller If Then 16 1 power up or undetermined 16 2 primary with qualified seconda
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