Rockwell Automation 1756-RMxx ControlLogix Enhanced Redundancy System User Manual User Manual
Controllogix enhanced redundancy system
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Table of contents
Document Outline
- ControlLogix Enhanced Redundancy System, 1756-UM535D-EN-P
- Important User Information
- Summary of Changes
- Table of Contents
- Preface
- Ch 1 - About Enhanced Redundancy Systems
- Ch 2 - Design an Enhanced Redundancy System
- Design an Enhanced Redundancy System
- Components of an Enhanced Redundancy System
- Table 4 - Components Available for Use in a Redundant Chassis Pair
- Figure 1 - Example ControlLogix Enhanced Redundancy System, Revision 19.053 or later, Using an EtherNet/IP Network
- Figure 2 - Example ControlLogix Enhanced Redundancy System, Revision 19.053 or later, Using a ControlNet Network
- 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
- EtherNet/IP Networks with Redundant Systems
- ControlNet Networks with Redundant Systems
- Other Communication Networks
- I/O Placement
- Using HMI
- Firmware Requirements
- Software Requirements
- Components of an Enhanced Redundancy System
- Design an Enhanced Redundancy System
- Ch 3 - Install the Enhanced Redundancy System
- Install the Enhanced Redundancy System
- Before You Begin
- Enhanced Redundancy System Quick Start
- 1. Install/update the workstation software and firmware bundle. (Refer to Step 1: Install the Software on page 53.)
- 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 H...
- 3. Plug in the fiber-optic communication cable to connect the redundancy modules in both chassis. See Step 3: Connect the Redundancy Modules via a Fiber-optic Cable on page 63.
- 4. Upgrade the redundant chassis firmware. See Step 4: Update Redundant Chassis Firmware on page 67.
- 5. Designate the primary chassis. See Step 5: Designate the Primary and Secondary Chassis on page 71.
- Enhanced Redundancy System Quick Start
- Install an Enhanced Redundancy System
- Step 1: Install the Software
- Step 2: Install the Hardware
- Install the First Chassis and its Components
- Install the Chassis and Power Supply
- Install the Communication Modules
- Install a Controller
- Install the Redundancy Module
- Environment and Enclosure
- Prevent Electrostatic Discharge
- Removal and Insertion Under Power (RIUP)
- European Hazardous Location Approval
- Safety-related Programmable Electronic Systems
- Optical Ports
- Small Form-factor Pluggable
- North American Hazardous Location Approval
- Laser Radiation Ports
- Install the Second Chassis
- Step 3: Connect the Redundancy Modules via a Fiber-optic Cable
- Table 11 - Fiber-optic Cable Length
- Connect the Fiber-optic Communication Cable to Redundant Channels
- 1. Remove the black protective plug on the first redundancy module in the redundant chassis pair.
- 2. Remove the protective caps from the cable.
- 3. Plug the cable connectors into the first redundancy module.
- 4. If redundant fiber crossload cable is required, install the second fiber cable into the remaining port.
- 5. The first end of the fiber cable should plug into the CH1 port on the first chassis and the matching end should plug into the matching CH1 port on the second chassis.
- Connect the Fiber-optic Communication Cable to Single Channels
- Fiber-optic Cable
- Step 4: Update Redundant Chassis Firmware
- Upgrade the Firmware in the First Chassis
- 1. Apply power to the chassis.
- 2. Set the mode switch on the controller to REM.
- 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 pr...
- 4. Launch ControlFLASH software and click Next to begin the update process.
- 5. Select the module’s catalog number (upgrade the redundancy module first) and click Next.
- 6. Expand the network driver to locate the redundancy module or module you are upgrading.
- 7. Select the module and click OK.
- 8. Select the firmware revision you want to update to and click Next.
- 9. Click Finish.
- 10. Click Yes.
- 11. Click OK.
- 12. Verify that the redundancy module status displays PRIM, indicating a successful upgrade.
- 13. Complete steps 4…12 for each module in the chassis.
- Upgrade the Firmware in the Second Chassis
- Upgrade the Firmware in the First Chassis
- Step 5: Designate the Primary and Secondary Chassis
- 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.
- 3. Apply power to the chassis you want to designate as the secondary chassis.
- 4. Verify primary and secondary chassis designations by viewing the module status display and the PRI indicator.
- After Designation
- Conversion from a Nonredundant to a Redundant System
- Qualification Status via the RMCT
- Reset the Redundancy Module
- Remove or Replace the Redundancy Module
- Notes:
- Before You Begin
- Install the Enhanced Redundancy System
- Ch 4 - Configure the ENET Network
- Configure the EtherNet/IP Network
- 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
- Figure 22 - Example DLR Network
- 1. Active Supervisor Node - The network requires one active supervisor node per DLR network that executes these tasks:
- 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.
- 1. Install and connect devices on the DLR network but leave at least one connection open.
- 2. Configure and enable one active supervisor and any back-up nodes on the network.
- 3. Complete the physical connections on the network to establish a complete and fully functioning DLR network. This figure shows the example DLR network on page 91 with all physical connections complete.
- 4. Verify supervisor configuration and overall DLR network status with either of these tools:
- Configure the EtherNet/IP Network
- Ch 5 - Configure the CNET Network
- Configure the ControlNet Network
- Produce/Consume Connections
- Network Update Time
- Use a Scheduled or Unscheduled Network
- Schedule a New Network
- 1. Turn on the power to each chassis.
- 2. Start RSNetWorx for ControlNet software.
- 3. From the File menu, choose New.
- 4. From the Network menu, choose Online.
- 5. Select your ControlNet network and click OK.
- 6. Check Edits Enabled.
- 7. From the Network menu, choose Properties.
- 8. In the Network Parameters tab, enter the parameters that are appropriate for your system.
- 9. Click OK.
- 10. From the Network menu, choose Single Pass Browse.
- 11. From the File menu, choose Save.
- 12. Type a name for the file that stores the network configuration, then click Save.
- 13. Click Optimize and re-write Schedule for all Connections (default) and click OK.
- Update an Existing Scheduled Network
- 1. Turn on the power to each chassis.
- 2. Start RSNetWorx for ControlNet software.
- 3. From the File menu, choose Open.
- 4. Select the file for the network and click Open.
- 5. From the Network menu, choose Online.
- 6. Click Edits Enabled.
- 7. From the Network menu, choose Properties.
- 8. In the Network Parameters tab, update the parameters specific to your system.
- 9. Click OK.
- 10. From the Network menu, choose Single Pass Browse.
- 11. From the File menu, choose Save.
- 12. Click Optimize and re-write schedule for all connections and click OK.
- 13. Click OK.
- Check the Network Keeper States
- 1. In RSNetWorx for ControlNet software, from the Network menu choose Keeper Status.
- 2. Verify that one keeper-capable device outside the redundant chassis is indicated as active and valid.
- 3. Verify that all of the keeper-capable devices on the network are valid.
- 4. Verify that all of the nodes on the network have the same keeper signature.
- Save the Project for Each Primary Controller
- Automatic Keeper Crossloads
- 1. Disconnect the module from the ControlNet network and remove it from the chassis.
- 2. Set the node address switches to 00.
- 3. Insert the module back into the chassis and wait for the status display to indicate Reset Complete.
- 4. Remove the module and set the node address switches to the intended node address.
- 5. Insert the module into the chassis.
- Notes:
- Configure the ControlNet Network
- Ch 6 - Configure the Redundancy Modules
- Configure the Redundancy Modules
- About the Redundancy Module Configuration Tool (RMCT)
- Determine if Further Configuration is Required
- Use the RMCT
- Identify the RMCT Version
- 1. Once on the site, choose Control Hardware.
- 2. On the Firmware Updates page, choose the latest firmware bundle.
- 3. Download if different from your current module’s firmware.
- 1. Launch RSLinx Classic software.
- 2. Click the RSWho icon.
- 3. Right-click your redundancy module and choose Module Configuration.
- 4. Right-click the title bar and choose About.
- Update the RMCT Version
- Identify the RMCT Version
- Module Info Tab
- Configuration Tab
- Synchronization Tab
- Synchronization Status Tab
- Event Log Tab
- Table 20 - Settings for Event Log Views
- Figure 29 - Settings for Event Log Views
- Event Classifications
- Access Extended Information About an Event
- Interpret an Event’s Extended Information
- Export Event Log Data
- Export Selection
- 1. Launch RSLinx Classic communication software and browse to the redundancy modules.
- 2. Right-click the primary redundancy module and choose Module Configuration.
- 3. In the Auto-Update area, click Off to keep the log from updating.
- 4. In the Partner Log area, click Close.
- 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.
- 6. Click Export Selection.
- 7. Complete these steps on the Export Event Log dialog box.
- 8. Click Export.
- 9. If you want to export the secondary redundancy module log for a complete system view complete step 1…step 8.
- Export All
- 1. Launch RSLinx Classic communication software and browse to the redundancy modules.
- 2. Right-click the primary redundancy module and choose Module Configuration.
- 3. On the Event Log tab, click Export All.
- 4. Click OK.
- 5. Select the redundancy module in the partner redundant chassis.
- 6. Complete these steps on the Export Event Log dialog box.
- 7. Click Export.
- Export Selection
- Clear a Fault
- System Update Tab
- System Event History
- Using Dual Fiber Ports with the 1756-RM2/A Redundancy Module
- Notes:
- Configure the Redundancy Modules
- Ch 7 - Program a Redundant Controller
- Program the Redundant Controller
- Configure the Redundant Controller
- 1. Open or create a RSLogix 5000 project for your redundant controller.
- 2. Access the Controller Properties dialog box for the 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:
- 5. Click the Advanced tab.
- 6. Verify that Match Project to Controller is unchecked.
- Crossloads, Synchronization, and Switchovers
- Crossloads and Scan Time
- Program to Minimize Scan Times
- Use a 1756-L7x Controller with a 1756-RM2/A Redundancy Module
- Use Multiple Controllers
- Minimize the Number of Programs
- Manage Tags for Efficient Crossloads
- Use Concise Programming
- Program to Maintain Data Integrity
- Array (File)/Shift Instructions
- 1. If a higher priority task interrupts one of the Array (File)/Shift instructions, the partially-shifted array values are crossloaded to the secondary controller.
- 2. If a switchover occurs before the instruction completes its execution, data remains only partially shifted.
- 3. After a switchover, the secondary controller starts its executing at the beginning of the program. When it reaches the partially-executed instruction, it shifts the data again.
- Buffering Critical Data
- Scan-dependent Logic
- Array (File)/Shift Instructions
- 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
- Store a Redundancy Project to Nonvolatile Memory
- Store a Project While the Controller is in Program or Remote Program Mode
- 1. Verify that the redundant chassis are synchronized. If they are not synchronized, synchronize them.
- 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.
- 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.
- 9. Complete steps 6…8 to store the project in nonvolatile memory of the secondary controller.
- 10. In RSLinx Classic software, open the RMCT for one of the redundancy modules in the redundant pair.
- 11. In the Synchronization tab, click Synchronize Secondary.
- 12. In the Configuration tab, set the Auto-Synchronization option to your desired setting.
- Store a Project While a System is Running
- 1. Verify that the redundant chassis are synchronized.
- 2. In the RMCT, access the Configuration tab and set the Auto- Configuration parameter to Never.
- 3. In the Synchronization tab, click Disqualify Secondary.
- 4. Go online with the secondary controller.
- 5. Open the Controller Properties dialog box and click the Nonvolatile Memory tab.
- 6. Click Load/Store then <-- Store to store the project in nonvolatile memory.
- 7. In the RMCT, click the Synchronization tab.
- 8. Click Synchronize Secondary and wait for the system to synchronize.
- 9. Click Initiate Switchover.
- 10. Go online with the new secondary controller.
- 11. Complete steps 5 and 6 to store the project.
- 12. In the RMCT, click the Configuration tab and set the Auto- Configuration to your desired setting.
- 13. In the Synchronization tab, click Synchronize Secondary.
- Load a Project
- Store a Project While the Controller is in Program or Remote Program Mode
- Online Edits
- Notes:
- Configure the Redundant Controller
- Program the Redundant Controller
- Ch 8 - Monitor and Maintain an Enhanced Redundancy System
- Ch 9 - Troubleshoot a Redundant System
- Troubleshoot a Redundant System
- General Troubleshooting Tasks
- Check the Module Status Indicators
- Use RSLogix 5000 Software to View Errors
- 1. Go online with the redundant controller.
- 2. Either click Primary or Secondary, depending on the controller you are online with.
- 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.
- 6. If necessary, reference these resources:
- Redundant Controller Major Fault Codes
- Use the RMCT for Synchronization Attempts and Status
- Use the RMCT Event Log
- Interpret Event Log Information
- 1. Open the RMCT and click the Event Log tab.
- 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.
- 4. Then, locate the matching time entry in the B chassis event log. This will display the disqualification code on the Event line.
- 5. Work back in time (up the lines of preceding events), to locate the point that a switchover or disqualifying event occurred.
- 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.
- 7. After you have located an event entry related to the anomaly you are troubleshooting, double-click the event to view Extended Event Information.
- 8. View the Description and Extended Data Definitions.
- Export All Event Logs
- 1. Open the RMCT on the 1756-RM module in the primary chassis and click the Event Log tab.
- 2. Click Export All.
- 3. Click OK.
- 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.
- 7. Click OK.
- Export Diagnostics
- 1. Click Clear Fault if it is enabled, as it may first be necessary to clear any faults before using Export Diagnostics.
- 2. Click Export Diagnostics.
- 3. Click OK to specify the communication path via RSWho software.
- 4. Select the communication path to the partner or secondary module and click OK.
- 5. Name and save the export file.
- 6. Click Export.
- 7. Click OK.
- Contact Rockwell Automation Technical Support
- Interpret Event Log Information
- Keeper Status Causing Synchronize Failure
- Partner Network Connection Lost
- 1. Open RSLinx Classic software and access the RMCT of the primary redundancy module.
- 2. Locate the last event that indicates successful qualification and status.
- 3. Open the Event Log for the secondary chassis because the cause of the switchover is not apparent.
- 4. Use the time of the switchover event found in the primary chassis to identify the corresponding event in the secondary chassis.
- 5. Confirm the ControlNet connection error by browsing the network in RSLinx Classic software.
- Redundancy Module Connection Lost
- Redundancy Module Missing
- Qualification Aborted Due to a Nonredundant Controller
- 1. If not already open, open the RMCT of the primary module.
- 2. Click the Synchronization tab and view the Recent Synchronization Status Attempts log.
- 3. Select the aborted attempt to view the description
- 4. Click the Synchronization Status tab to check the compatibility between modules.
- 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.
- Controller Events
- Troubleshoot a Redundant System
- App A - Status Indicators
- App B - Event Log Descriptions
- App C - Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System
- Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System
- Upgrade from a Standard Redundancy System
- Upgrade System Components
- 1. Verify that the standard redundancy system is offline.
- 2. Remove power from both the primary and secondary chassis.
- Upgrade the System Software
- Upgrade the Controllers
- Replace Communication Modules
- Steps After System Components Upgrade
- 1. Apply power to the primary chassis.
- 2. Update and load the controller program.
- 3. If used, reschedule the ControlNet network.
- 4. Place the primary controller in Run mode.
- 5. Apply power to the secondary chassis.
- 6. If your Auto-Synchronization parameter is set at Never or Conditional Disable, use the synchronization commands in the Synchronization tab of the RMCT to qualify and synchronize your system.
- Upgrade Ethernet Modules When Rotary Switches Are Set between 2…254
- 1. Set the mode switch of the primary and secondary controllers to REM.
- 2. Open RSLinx Classic software and browse to the redundancy module.
- 3. Right-click the redundancy module and choose Module Configuration.
- 4. Click the Configuration tab.
- 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.
- 9. Click OK.
- 10. Make a note of the primary Ethernet module’s Port Configuration including the following:
- 11. Disconnect the Ethernet cable or cables from the secondary Ethernet module.
- 12. Remove the secondary Ethernet module from the secondary chassis.
- 13. Reinsert the secondary Ethernet module into the secondary chassis.
- 14. Bridging across the backplane (or via the Ethernet module’s USB port), configure the secondary Ethernet module’s Port Configuration to match the primary Ethernet module’s Port Configuration from step 10.
- 15. Update the secondary Ethernet module to firmware revision 5.008 by following these steps.
- 16. After the update completes, reconnect the Ethernet cable or cables to the secondary Ethernet module and wait for communication to resume on the network.
- 17. Repeat steps 10…16 for all Ethernet modules that have their rotary switches set between 2…254.
- 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.
- 21. Click Synchronize Secondary, then click Yes.
- 22. After the redundant chassis pair synchronizes, click Initiate Switchover from the Synchronization tab in the RMCT, then click Yes.
- 23. In RSLinx Classic software, select Module Configuration on the new primary Ethernet communication module.
- 24. Click the Port Configuration tab and change the Gateway address from 0.0.0.0 to 192.168.1.1.
- 25. Click Apply, then click OK.
- 26. Disconnect the Ethernet cable or cables from the secondary Ethernet module.
- 27. In ControlFLASH software, bridge across the backplane (or use the Ethernet module’s USB port), and update the new secondary Ethernet module to firmware revision 5.008.
- 28. After the update completes, reconnect the Ethernet cable or cables to the secondary Ethernet module and wait for communication to resume on the network.
- 29. Repeat steps 23…28 for all 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.
- 33. Click Synchronize Secondary, then click Yes.
- 34. After the redundant chassis pair synchronizes, select Initiate Switchover from the Synchronization tab in the RMCT, then click Yes.
- 35. Remove the new secondary Ethernet module from the chassis and reset the rotary switches back to their original setting from 999.
- 36. Reinsert the secondary Ethernet module back in the chassis and wait until network communication resumes.
- 37. Repeat steps 35…36 for all Ethernet modules that have their rotary switches set between 2…254.
- Upgrade by Using Redundancy System Update
- 1. Step 1: Before You Begin
- 2. Step 2: Upgrade the Workstation Software
- 3. Step 3: Download and Install the Redundancy Firmware Bundle
- 4. Step 4: Upgrade the Redundancy Module Configuration Tool
- 5. Step 5: Add the EDS Files
- 6. Step 6: Prepare the Redundant Chassis for the Firmware Upgrade
- 7. Step 7: Upgrade the Primary Chassis Redundancy Module Firmware
- 8. Step 8: Upgrade the Secondary Redundancy Module Firmware and All Other Modules’ Firmware in the Secondary Chassis
- 9. Step 9: Prepare the RSLogix 5000 Project for the Upgrade
- 10. Step 10: Lock the System and Initiate a Switchover to Upgrade
- 11. Step 11: Upgrade the New Secondary Chassis Firmware
- 12. Step 12: Synchronize the Redundant Chassis
- Step 1: Before You Begin
- Step 2: Upgrade the Workstation Software
- Step 3: Download and Install the Redundancy Firmware Bundle
- 1. Click the Downloads link on the Get Support Now menu.
- 2. Click Firmware Updates under Additional Resources.
- 3. Click Control Hardware.
- 4. Click the 1756-Lxx Enhanced Redundancy Bundle file.
- 5. Enter your Serial Number.
- 6. Click Qualify For Update.
- 7. Click Finish when the Qualified For Update window appears.
- 8. Download the zipped file.
- 9. Install the Redundancy Firmware Bundle.
- Step 4: Upgrade the Redundancy Module Configuration Tool
- Verify Your RMCT Version
- Step 5: Add the EDS Files
- Step 6: Prepare the Redundant Chassis for the Firmware Upgrade
- 1. Set the mode switch of the primary and secondary controllers to REM.
- 2. Open RSLinx Classic software and browse to the redundancy module.
- 3. Right-click the redundancy module and select Module Configuration to open the RMCT.
- 4. Click the Configuration tab in the RMCT.
- 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.
- 9. Click OK and close the RMCT.
- Step 7: Upgrade the Primary Chassis Redundancy Module Firmware
- Step 8: Upgrade the Secondary Redundancy Module Firmware and All Other Modules’ Firmware in the Secondary Chassis
- 1. Launch ControlFLASH software and click Next.
- 2. Select the redundancy module catalog number and click Next.
- 3. Browse to the module and select it.
- 4. Click OK.
- 5. Select the firmware revision to upgrade to and click Next.
- 6. Click Finish.
- 7. If you are replacing or upgrading your controller hardware, remove the controller from the secondary chassis and replace it with the new controller.
- 8. Complete steps 2…7 for each module in the secondary chassis, including a new controller, if applicable.
- Step 9: Prepare the RSLogix 5000 Project for the Upgrade
- 1. Launch RSLogix 5000 software and go online with the primary controller.
- 2. Verify that the watchdog time is set to a value that corresponds with the requirements of the enhanced redundancy system revision and your application.
- 3. Cancel or assemble any pending test edits.
- 4. Remove all Sequential Function Chart (SFC) forces from the project.
- 5. Verify that no changes need to be made to the following:
- 6. If you are upgrading an enhanced redundancy system, revision 16.81 or earlier, disable CST Mastership.
- 7. Configure the controllers and communication modules in the redundant chassis pair as necessary.
- 8. Save the project.
- 9. Go offline.
- 10. Click Controller Properties.
- 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.
- 14. Click OK.
- 15. Access the Module Properties for each communication module in the chassis and specify the module firmware revision to which you are upgrading.
- 16. Save the project.
- 17. Download the project to the secondary controller.
- 18. After the download is complete, go offline.
- Step 10: Lock the System and Initiate a Switchover to Upgrade
- 1. Open the RMCT for the redundancy module in the primary chassis by right-clicking on the RM module in RSLinx Classic software and selecting Module Configuration.
- 2. Click the System Update tab.
- 3. Click Lock For Update, then click Yes.
- 4. Wait for the system to lock.
- 5. Click Initiate Locked Switchover, then click Yes.
- Step 11: Upgrade the New Secondary Chassis Firmware
- 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. Select the module catalog number and click Next.
- 4. Browse to the module and select it.
- 5. Click OK.
- 6. Select the firmware revision to upgrade to and click Next.
- 7. Click Finish.
- 8. Complete steps 2 …7 for each module in the new secondary chassis, including the new controllers, if applicable.
- Step 12: Synchronize the Redundant Chassis
- 1. Launch the RMCT for the redundancy module in the primary chassis by right-clicking on the module in RSLinx Classic software and selecting Module Configuration.
- 2. From the Auto-Synchronization pull-down menu, choose the frequency that suits your application.
- 3. Click Apply, then click Yes.
- 4. Synchronize the chassis.
- 5. Set the redundancy module date and time according to your preference.
- 6. Click OK.
- 7. Close the RMCT.
- Replace 1756-RM/A or 1756- RM/B Redundancy Modules with 1756-RM2/A Redundancy Modules
- 1. Install the compatible version of the RMCT software.
- 2. Set the Auto-Synchronization option in the Configuration tab of the RMCT to Never.
- 3. Using the RMCT, disqualify the redundant chassis pair (if not already disqualified).
- 4. Unplug the fiber cable on both of the redundancy modules.
- 5. Close any open RMCT sessions connected to the current redundancy modules being replaced.
- 6. Remove the redundancy module pair (in any order) from the redundant chassis.
- 7. Insert the 1756-RM2/A redundancy module pair (in any order) in the redundant chassis into the same slots as the redundancy modules.
- 8. If not already installed, install the EDS file for the 1756-RM2/A module by uploading it from the module by using RSLinx Classic software.
- 9. Update to the appropriate firmware revision in the primary and secondary 1756-RM2/A modules.
- 10. Reconnect the fiber cable on either CH1 or CH2 of the 1756-RM2/A redundancy module.
- 11. Optional: Connect a second fiber cable on the remaining channel if fiber redundancy is desired.
- 12. Wait for at least 45 seconds after connecting one of the fiber cables.
- 13. Launch the RMCT again for the newly-installed 1756-RM2/A modules.
- 14. Set the Auto-Synchronization option in the Configuration tab back to the original value or to a new desired value.
- 15. Using the RMCT, synchronize the system again (if it is not already qualified).
- Upgrade from a Standard Redundancy System or to Another Enhanced Redundancy System
- App D - Convert from a Nonredundant System
- Convert from a Nonredundant System
- Update the Configuration in 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.
- 2. Copy the I/O modules and paste them into the chassis of the newly-added communication module.
- 3. Delete the I/O modules from the controller chassis configuration.
- 4. Continue by completing the procedures to Replace Local I/O Tags and to Replace Aliases to Local I/O Tags.
- Replace Local I/O Tags
- 1. Open the routine where the local I/O tags need to be updated.
- 2. Press CTRL+H to open the Replace in Routines dialog box.
- 3. From the Find What pull-down menu, choose Local:.
- 4. From the Replace With pull-down menu, choose the name of the communication module where the remote I/O was placed.
- 5. From the Find Where pull-down menu, choose All Routines.
- 6. Click Find Within >>.
- 7. Select Ladder Diagrams.
- 8. Check Instruction Operands.
- 9. Click Replace All.
- Replace Aliases to Local I/O Tags
- 1. In RSLogix 5000 software, open the Controller Tags.
- 2. Press CTRL+H to open the Replace Tags dialog box.
- 3. From the Find What pull-down menu, choose Local:.
- 4. From the Replace With pull-down menu, choose the name of the communication module where the remote I/O was placed.
- 5. From the Find Where pull-down menu, choose All Tags.
- 6. Click Find Within >>.
- 7. Select Alias and click Replace All.
- Remove Other Modules from the Controller Chassis
- Add an Identical Chassis
- Upgrade to Enhanced Redundancy Firmware
- Update the Controller Revision and Download the Project
- Notes:
- Update the Configuration in RSLogix 5000 Software
- Convert from a Nonredundant System
- App E - Redundancy Object Attributes
- App F - Enhanced Redundancy System Checklists
- App G - Enhanced Redundancy Revision History
- Back Cover