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ControlLogix Enhanced Redundancy System User Manual

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ControlLogix Enhanced Redundancy SystemCatalog Numbers 1756-CN2, 1756-CN2R, 1756-CN2RXT, 1756-EN2T, 1756-EN2TXT, 1756-L61, 1756-L62, 1756-L63, 1756-L63XT, 1756-L64User ManualImportant User InformationSolid state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.Throughout this manual, when necessary, we use notes to make you aware of safety considerations.Allen-Bradley, ControlLogix, ControlLogix-XT, Logix5000, FactoryTalk, FactoryTalk View, RSLinx Classic, RSLinx Enterprise, RSLogix 5000, RSNetWorx for ControlNet, Rockwell Automation, Rockwell Software, and TechConnect are trademarks of Rockwell Automation, Inc.Trademarks not belonging to Rockwell Automation are property of their respective companies.WARNINGIdentifies 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.IMPORTANTIdentifies information that is critical for successful application and understanding of the product.ATTENTIONIdentifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequenceSHOCK HAZARDLabels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.BURN HAZARDLabels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.5Publication 1756-UM535A-EN-P - October 20095Table of ContentsPrefacePublication Scope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Chapter 1About Enhanced Redundancy SystemsFeatures of the Enhanced Redundancy System. . . . . . . . . . . 13Enhanced versus Standard Redundancy . . . . . . . . . . . . . 14Enhanced Redundancy System Components. . . . . . . . . . . . . 15Example of an Enhanced Redundancy System. . . . . . . . . 16Enhanced Redundancy System Operations. . . . . . . . . . . . . . 17System Qualification and Synchronization. . . . . . . . . . . . 17Switchovers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Chapter 2Design an Enhanced Redundancy SystemRedundant Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Chassis and Modules for Use as the Redundant Chassis. . 22Communication Modules in Redundant Chassis. . . . . . . . 23Plan for Communication Module Connections. . . . . . . . . 24Controllers in Redundant Chassis . . . . . . . . . . . . . . . . . . 25Plan for Controller Connections . . . . . . . . . . . . . . . . . . . 26Redundant Power Supplies. . . . . . . . . . . . . . . . . . . . . . . 27Redundant Chassis Configuration Requirements. . . . . . . . . . 28Upgrading Redundant System Hardware . . . . . . . . . . . . . . . 28ControlNet Networks for Redundant Systems. . . . . . . . . . . . 29ControlNet Network Requirements. . . . . . . . . . . . . . . . . 29Redundant ControlNet Media. . . . . . . . . . . . . . . . . . . . . 32EtherNet/IP Networks with Redundant Systems . . . . . . . . . . 33Plan for Communication Delays with EtherNet/IP Networks . . . . . . . . . . . . . . . . . . . . . . . . . . 33Redundant Media Not Available with EtherNet/IP Networks . . . . . . . . . . . . . . . . . . . . . . . . . . 33Determine Use of IP Address Swapping . . . . . . . . . . . . . 34Using IP Address Swapping . . . . . . . . . . . . . . . . . . . . . . 34Other Communication Networks . . . . . . . . . . . . . . . . . . . . . 35I/O Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Using HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38HMI Connected Via an EtherNet/IP Network. . . . . . . . . . 38HMI Connected Via a ControlNet Network . . . . . . . . . . . 39Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Required Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Optional Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416Publication 1756-UM535A-EN-P - October 2009Table of ContentsChapter 3Install the Enhanced Redundancy SystemAbout This Chapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Before You Begin. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Install Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Download Firmware and the RMCT. . . . . . . . . . . . . . . . . . . 44Install the Chassis and Power Supplies. . . . . . . . . . . . . . . . . 45Install the Controller and Communication Modules. . . . . . . . 45Install the Redundancy Modules . . . . . . . . . . . . . . . . . . . . . 46Connect the Fiber-Optic Cable. . . . . . . . . . . . . . . . . . . . . . . 47Install Remote Chassis and Modules. . . . . . . . . . . . . . . . . . . 48Upgrade Redundant Chassis Firmware. . . . . . . . . . . . . . . . . 48Designate the Primary and Secondary Chassis . . . . . . . . . . . 50After Designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Qualification Status via the RMCT. . . . . . . . . . . . . . . . . . 52Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Chapter 4Configure the ControlNet NetworkNetwork Update Time (NUT) . . . . . . . . . . . . . . . . . . . . . . . 55NUTs with Multiple ControlNet Networks. . . . . . . . . . . . 56Requested Packet Interval (RPI). . . . . . . . . . . . . . . . . . . . . . 57Estimate Switchover Response Time. . . . . . . . . . . . . . . . . . . 58Using a Scheduled or Unscheduled Network . . . . . . . . . . . . 58Use a Scheduled Network . . . . . . . . . . . . . . . . . . . . . . . 58Use an Unscheduled Network . . . . . . . . . . . . . . . . . . . . 59Adding Remote ControlNet Modules While Online . . . . . 59Schedule a New Network . . . . . . . . . . . . . . . . . . . . . . . . . . 60Update an Existing Scheduled Network . . . . . . . . . . . . . . . . 62Check the Network Keeper States . . . . . . . . . . . . . . . . . . . . 63Save the Project for Each Primary Controller. . . . . . . . . . 64Automatic Keeper Crossloads. . . . . . . . . . . . . . . . . . . . . 65Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Chapter 5Configure the EtherNet/IP NetworkIP Addresses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Static versus Dynamic IP Addresses . . . . . . . . . . . . . . . . 67Configure Redundant EtherNet/IP Modules . . . . . . . . . . . . . 68Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Options for Setting the IP Addresses of EtherNet/IP Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Half/Full Duplex Settings. . . . . . . . . . . . . . . . . . . . . . . . 70Using CIP Sync. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Publication 1756-UM535A-EN-P - October 20097Table of ContentsChapter 6Configure the 1756-RM or 1756-RMXT ModulesAbout the Redundancy Module Configuration Tool (RMCT) . 71Determine if Further Configuration is Required. . . . . . . . . . . 72Using the RMCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Identify the RMCT Version. . . . . . . . . . . . . . . . . . . . . . . 74Upgrade the RMCT Version . . . . . . . . . . . . . . . . . . . . . . 75Module Info Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76Configuration Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Auto-Synchronization. . . . . . . . . . . . . . . . . . . . . . . . . . . 78Chassis ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Enable User Program Control. . . . . . . . . . . . . . . . . . . . . 79Redundancy Module Date and Time. . . . . . . . . . . . . . . . 79Synchronization Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Commands in the Synchronization Tab. . . . . . . . . . . . . . 81Recent Synchronization Attempts Log. . . . . . . . . . . . . . . 83Synchronization Status Tab . . . . . . . . . . . . . . . . . . . . . . . . . 85Event Log Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Event Classifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . 87Accessing Extended Information About an Event. . . . . . . 89Interpreting an Event’s Extended Information . . . . . . . . . 90Exporting Event Log Data. . . . . . . . . . . . . . . . . . . . . . . . 91System Update Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94System Update Commands. . . . . . . . . . . . . . . . . . . . . . . 95System Update Lock Attempts . . . . . . . . . . . . . . . . . . . . 97Locked Switchover Attempts. . . . . . . . . . . . . . . . . . . . . . 99System Event History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100Edit a User Comment for a System Event . . . . . . . . . . . 101Saving System Event History. . . . . . . . . . . . . . . . . . . . . 101Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

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