Document Outline

• ControlLogix Enhanced Redundancy System, 1756-UM535D-EN-P
• Important User Information
• Summary of Changes
  • New and Updated Information
    • Table 1 - New and Updated Information
• Table of Contents
  • Notes:
• Preface
  • Additional Resources
    • Table 2 - Additional Documentation
    • Table 3 - Additional Documentation
• Ch 1 - About Enhanced Redundancy Systems
  • About Enhanced Redundancy Systems
    • Features of the ControlLogix Enhanced Redundancy System
      • Features Not Supported
    • Enhanced Redundancy System Components
      • I/O Modules in Enhanced Redundancy Systems
    • Enhanced Redundancy System Operations
      • System Qualification and Synchronization
      • Switchovers
        • HMI Blind Time Reduction on Ethernet During a Switchover
    • Restrictions
• 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
        • Redundant Chassis Configuration Requirements
          • Figure 3 - Example of Redundant Chassis Pair
      • Controllers in Redundant Chassis
        • Table 5 - Controller Features
        • Table 6 - Controller Compatibility
        • Plan for Controller Connections
      • Redundancy Modules in Redundant Chassis
      • Communication Modules in Redundant Chassis
        • Plan for Communication Module Connections
      • Power Supplies and Redundant Power Supplies in Enhanced Redundancy Systems
        • Redundant Power Supplies
          • Figure 4 - Redundant Power Supplies with Redundant Chassis
    • EtherNet/IP Networks with Redundant Systems
      • Table 7 - EtherNet/IP Communication Modules in Remote Chassis Minimum Firmware Requirements
      • EtherNet/IP Network Features in an Enhanced Redundancy System, Revision 19.052 or Later
      • IP Address Swapping
      • Unicast Functionality
      • Possible Communication Delays on EtherNet/IP Networks
        • Figure 5 - Configuration Used to Eliminate Communication Delays on Switchover
    • ControlNet Networks with Redundant Systems
      • ControlNet Network Requirements
        • Use at Least Four ControlNet Network Nodes
        • Assign Lowest Node Numbers to Remote ControlNet Modules
        • Set Partnered ControlNet Module Switches to the Same Address
          • Figure 6 - Example of Switch Address for Partnered ControlNet Modules
        • Reserve Consecutive Node Addresses for Partner Modules
          • Figure 7 - Example of Redundant ControlNet Modules at Consecutive Addresses
      • Redundant ControlNet Media
        • Figure 8 - Redundant ControlNet Media with Redundant ControlLogix Chassis
    • Other Communication Networks
      • Figure 9 - Example of Bridging to Remote I/O on Various Networks
      • Table 8 - Communication Networks Available For Use with Enhanced Redundancy Systems
    • I/O Placement
      • 1715 Redundant I/O Systems
        • Figure 10 - Example of I/O Placement Options
    • Using HMI
      • HMI Connected via an EtherNet/IP Network
      • HMI Connected via a ControlNet Network
        • Figure 11 - Connection from HMI Over a ControlNet Network
    • Firmware Requirements
    • Software Requirements
      • Required Software
      • Optional Software
• 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...
          • a. Determine the IP address for your Ethernet communication modules.
          • b. Set both Ethernet communication modules to the same IP address. (This rule also applies to ControlNet networks.) See Configure the EtherNet/IP Network on page 77.
        • 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.
    • Install an Enhanced Redundancy System
      • 1. Installing the software
      • 2. Installing the hardware
      • 3. Connecting the fiber-optic communication cable to the redundancy modules
      • 4. Updating the firmware
      • 5. Designating a primary and secondary chassis
    • Step 1: Install the Software
      • Install the Software
      • Add the EDS Files
    • Step 2: Install the Hardware
      • Install the First Chassis and its Components
        • Module Placement and Partnering
      • Install the Chassis and Power Supply
        • Table 9 - Installation Information for ControlLogix Chassis and Power Supplies
      • Install the Communication Modules
        • Table 10 - Communication Module Installation
      • Install a Controller
      • Install the Redundancy Module
        • Installation Requirements
      • 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
        • Figure 12 - 1756-RM2/A or 1756-RM2XT Modules
        • Figure 13 - 1756-RM/A or RM/B and 1756-RMXT Modules
        • 1. Align the circuit board with top and bottom guides in the chassis.
        • 2. Slide the module into the chassis, making sure the module backplane connector properly connects to the chassis backplane.
      • 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
        • 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 connector into the first redundancy module.
        • 4. Plug the remaining cable-connector end to the second redundancy module.
      • Fiber-optic Cable
        • Table 12 - Optical Power Budget Ranges
    • 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
        • 1. Apply power to the second chassis.
        • 2. Complete steps 3…12 in section Upgrade the Firmware in the First Chassis beginning on page 68 for the modules in the second chassis.
        • 3. Power off the second chassis after you have verified the successful upgrade of each module.
    • 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
        • Table 13 - Qualification Status Interpretation
      • Conversion from a Nonredundant to a Redundant System
      • Qualification Status via the RMCT
        • Figure 14 - RMCT Synchronization Status Tab
        • Figure 15 - Synchronization Status Tab for Chassis Compatibility
        • Figure 16 - Event Log with Qualification Events
      • Reset the Redundancy Module
      • Remove or Replace the Redundancy Module
        • 1. Push on upper and lower module tabs to disengage them.
        • 2. Slide the module out of the chassis.
    • Notes:
• Ch 4 - Configure the ENET Network
  • Configure the EtherNet/IP Network
    • Requested Packet Interval
      • CPU Usage
        • Table 14 - System Resource Utilization Table
    • Use IP Address Swapping
      • Determine Use of IP Address Swapping
      • Use IP Address Swapping
        • Figure 17 - EtherNet/IP Communication Modules’ IP Addresses During System Configuration
        • Figure 18 - EtherNet/IP Communication Modules’ IP Addresses After System Operation Begins
        • Figure 19 - IP Addresses in RSLinx Classic Software
      • Static versus Dynamic IP Addresses
      • Reset the IP Address for an EtherNet/IP Communication Module
    • Use CIP Sync
      • Figure 20 - Enhanced Redundancy System, Revision 19.052 or later, Using CIP Sync Technology
    • Use Produce/Consume Connections
      • Figure 21 - Example System Using Produced and Consumed Tags
    • Configure EtherNet/IP Communication Modules in a Redundant System
      • Before You Begin
      • Options for Setting the IP Addresses of EtherNet/IP Communication Modules
      • Half/Full Duplex Settings
    • 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.
        • Figure 23 - Normal DLR Network Operation
        • Figure 24 - Enhanced Redundancy System in a DLR Network
      • 1. Install and connect devices on the DLR network but leave at least one connection open.
        • Figure 25 - DLR Topology with One Connection Unmade
      • 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.
        • Figure 26 - Fully Connected DLR Network
      • 4. Verify supervisor configuration and overall DLR network status with either of these tools:
• Ch 5 - Configure the CNET Network
  • Configure the ControlNet Network
    • Produce/Consume Connections
      • Figure 27 - Example System Using Produced and Consumed Tags
    • Network Update Time
      • NUTs with Multiple ControlNet Networks
        • Figure 28 - Example of Two ControlNet Networks
        • Table 15 - Compatible NUT Values for Multiple ControlNet Networks
    • Use a Scheduled or Unscheduled Network
      • Use a Scheduled Network
      • Use an Unscheduled Network
      • Add Remote ControlNet Modules While Online
    • 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:
• Ch 6 - Configure the Redundancy Modules
  • Configure the Redundancy Modules
    • About the Redundancy Module Configuration Tool (RMCT)
      • Table 16 - Chassis Platform Configuration
    • 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
    • Module Info Tab
      • Table 17 - Module Info Tab - Parameters Indicated
    • Configuration Tab
      • Auto-Synchronization
      • Chassis ID
      • Enable User Program Control
      • Redundancy Module Date and Time
    • Synchronization Tab
      • Commands in the Synchronization Tab
      • Recent Synchronization Attempts Log
        • Table 18 - Recent Synchronization Attempts Log - Result Interpretations
        • Table 19 - Synchronization Interpretation
    • Synchronization Status Tab
    • Event Log Tab
      • Table 20 - Settings for Event Log Views
      • Figure 29 - Settings for Event Log Views
      • Event Classifications
        • Figure 30 - Event Classifications in the Event Log Tab
        • Table 21 - Classification Types
      • 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.
            • a. Specify a file name and location or use the default name and location.
            • b. Check CSV (Comma-Separated Value).
            • c. Check Include Extended Information.
          • 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.
            • a. Specify a file name and location or use the default name and location.
            • b. Check CSV (Comma-Separated Value).
            • c. Check Export Diagnostic Data.
            • d. Check Include Extended Information.
          • 7. Click Export.
      • Clear a Fault
    • System Update Tab
      • System Update Commands
        • Lock For Update
          • Figure 31 - Lock for Update Status Updates
        • Abort System Lock
        • Initiate Locked Switchover
          • Figure 32 - Illustration of Switchover
      • System Update Lock Attempts
        • Table 22 - System Update Lock Attempts Log Statuses
      • Locked Switchover Attempts
        • Table 23 - Locked Switchover Event Log Statuses
    • System Event History
      • Edit a User Comment for a System Event
      • Save System Event History
    • Using Dual Fiber Ports with the 1756-RM2/A Redundancy Module
      • Fiber Channel Switchover
      • Configuration
      • Monitoring and Repair
    • Notes:
• 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
      • Changing Crossload and Synchronization Settings
      • Default Crossload and Synchronization Settings
      • Recommended Task Types
      • Continuous Task After Switchover
        • Continuous Task with Crossloads at Each Program End
          • Figure 33 - Program Execution After a Switchover (crossload after each program)
        • Continuous Task with Varying Crossloads at Program End
          • Figure 34 - Program Execution After a Switchover (no crossload after each program)
      • Multiple Periodic Tasks
        • Figure 35 - Normal Periodic Task Execution (no switchover)
        • Figure 36 - Periodic Task Execution After Switchover When Configured to Crossload After Programs
        • Figure 37 - Periodic Task Execution After Switchover When Configured Not to Crossload After Programs
    • Crossloads and Scan Time
      • Figure 38 - Crossload and Scan Time
      • Estimate the Crossload Time
      • Redundancy Object Attributes for Crossload Times
      • Equation for Estimating Crossload Times
        • 1756-L6x Controllers
        • 1756-L7x Controllers
          • Table 24 - Crossload Times for 1756-L7x Controllers
    • 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
        • Figure 39 - Use of Multiple Routines (preferred)
      • Manage Tags for Efficient Crossloads
        • Delete Unused Tags
        • Use Arrays and User-Defined Data Types
          • Figure 40 - Example Savings with the Use of an Array
        • Group Data Types Together in User-Defined Data Types
          • Figure 41 - Example of Bytes Saved by Grouping Like Data
          • Figure 42 - Data Types Grouped
        • Group Data into Arrays of User-Defined Data Types by Frequency of Use
          • Figure 43 - Tags Grouped into User-Defined Data Types by Frequency of Use
        • Use DINT Tags Instead of SINT or INT Tags when Possible
      • Use Concise Programming
        • Execute an Instruction Only when Needed
          • Figure 44 - Precondition Used with ADD Instruction
          • Figure 45 - Efficient Precondition Use
    • 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
          • Figure 46 - Using a Buffer to Maintain Data During Shift
      • Scan-dependent Logic
        • Table 25 - Scan-dependent Logic
        • Bind Dependent Instructions with UID and UIE Instructions
          • Figure 47 - Scan-dependent Instructions Bound with UID and UIE Instructions
    • Program to Optimize Task Execution
      • Table 26 - Communication Tasks during Scheduled and Unscheduled Periods
      • Table 27 - Methods to Increase Service Communication Periods
      • Specify a Larger System Overhead Time Slice
        • Table 28 - Overhead Time Slice
        • System Overhead Time Slice Examples
          • Figure 48 - System Overhead Time Slice Set to 20%
          • Figure 49 - System Overhead Time Slice Set to 33%
      • Change the System Overhead Time Slice
        • Options for During the Unused System Overhead Time Slice
      • Use Periodic Tasks
        • Figure 50 - Periodic Task Execution and Service Communication
        • Example of Periodic Task Configurations
        • Tuning the Period Specified
    • Program to Obtain System Status
      • Figure 51 - GSV Instruction to Get Chassis ID
    • Program Logic to Run After a Switchover
      • Figure 52 - Precondition Used to Run Logic After Switchover - Ladder Logic
    • Use Messages for Redundancy Commands
      • Verify User Program Control
        • Figure 53 - Enable User Program Control in the RMCT
      • Use an Unconnected Message
      • Configure the MSG Instruction
        • Initiate a Switchover
          • Table 29 - MSG Instruction to Initiate a Switchover
          • Table 30 - MSG Instruction Behavior During a Switchover
        • Disqualify the Secondary Chassis
          • Table 31 - Disqualify the Secondary Chassis
        • Synchronize the Secondary Chassis
          • Table 32 - Synchronize the Secondary Chassis
        • Set the Redundancy Module Date and Time
          • Table 33 - Set Wallclock Time
    • Set the Task Watchdog
      • Figure 54 - Watchdog Configured for Redundancy Switchover
      • Figure 55 - Watchdog Not Configured for Redundancy Switchover
      • Minimum Value for the Watchdog Time
        • 1. Monitor the Max Scan Time for each task while the redundant chassis pair is synchronized.
        • 2. Set the Watchdog times for each task to 3 times the Max Scan Time.
        • 3. Use the Logix5000 Task Monitor Tool to configure each Task Period.
    • 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
    • Online Edits
      • Support for Partial Import Online
      • Plan for Test Edits
        • Figure 56 - Retain Test Edits on Switchover
      • Finalize Edits with Caution
        • Figure 57 - Test Edits Before Finalizing
      • Reserve Memory for Tags and Logic
        • Table 34 - Possible Memory Usage Setting Change
    • Notes:
• Ch 8 - Monitor and Maintain an Enhanced Redundancy System
  • Monitor and Maintain an Enhanced Redundancy System
    • Tasks to Monitor the System
    • Controller Logging
      • Controller Log
      • Controller Logging in Enhanced Redundancy Systems
    • Use Programming to Monitor System Status
    • Verify Date and Time Settings
    • Verify System Qualification
      • Check Qualification Status via Module Status Displays
        • Table 35 - Synchronized System
        • Table 36 - Qualifying System
        • Table 37 - System with a Primary and Disqualified Secondary
        • Example of Qualified and Disqualified Status Indicators
      • Check Qualification Status via the RMCT
    • Conduct a Test Switchover
      • 1. In RSLinx Classic software, access the RMCT for the primary redundancy module.
      • 2. Click the Synchronization tab.
      • 3. Click Initiate Switchover.
      • 4. Click Yes.
      • 5. View your HMI or other status-monitoring device to verify that the switchover was successful.
      • Synchronization After a Switchover
    • Check the ControlNet Module Status
      • 1. In RSLinx Classic software, open the Module Statistics for the ControlNet module.
      • 2. Click the Connection Manager tab.
      • CPU Usage
      • Connections Used
      • Monitor the ControlNet Network
• Ch 9 - Troubleshoot a Redundant System
  • Troubleshoot a Redundant System
    • General Troubleshooting Tasks
    • Check the Module Status Indicators
      • Figure 58 - Steady or Flashing Red Indicators that Indicate Errors on 1756-RM2/A or 1756-RM2XT Modules
      • Figure 59 - Steady of Flashing Red Indicators that Indicate Errors on 1756-RM/1756-RMXT Modules
      • Figure 60 - Module Status Displays For Chassis with 1756-L6x and 1756-L7x Controllers
    • 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
        • Table 38 - Redundant Controller Major Fault Codes
    • Use the RMCT for Synchronization Attempts and Status
      • Recent Synchronization Attempts
        • Figure 61 - Example of an Unsuccessful Synchronization Attempt
      • Module-level Synchronization 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.
          • Table 39 - Possible Qualification Status Indicators
      • 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
    • Keeper Status Causing Synchronize Failure
      • Check the Module Status Display
      • Check Keeper Status in RSNetWorx for ControlNet Software
        • Figure 62 - Network Keeper Status
        • Valid Keepers and Signatures
      • Valid Keeper Status and Signatures
        • Unconfigured Keeper
          • Figure 63 - Keeper Status - Unconfigured
        • Keeper Signature Mismatch
          • Figure 64 - Keeper Status - Signature Mismatch
    • 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
      • Figure 65 - Event Log with Partner RM Screamed Event
      • Figure 66 - Missing Redundancy Module in RSLinx Classic Software
    • 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
• App A - Status Indicators
  • Status Indicators
    • Redundancy Module Status Indicators
      • 1756-RM2/A and 1756-RM2XT Status Indicators
        • Figure 67 - Redundancy Module Status Indicators for 1756-RM2/A and 1756-RM2XT Modules
        • Module Status Display
          • Table 40 - Module Status Display
        • OK Status Indicators
          • Table 41 - OK Status Indicator
        • CH1 and CH2 Status Indicators
          • Table 42 - CH1 and CH2 Status Indicators
        • SFP Error Message
      • 1756-RM/A and 1756-RM/B Status Indicators
        • Figure 68 - Redundancy Module Status Indicators for 1756-RM and 1756-RMXT Modules
        • Module Status Display
          • Table 43 - Module Status Display
        • OK Status Indicators
          • Table 44 - OK Status Indicator
        • Communication Status Indicator
          • Table 45 - Communication Status Indicator
        • Chassis State Status Indicator
      • Redundancy Module Fault Codes and Display Messages
        • Table 46 - Module Fault Codes
        • Event Log When Redundancy Module Experiences Fault
        • Module Status Display
          • Table 47 - Major Fault Code Messages
            • 1. Reset the module.
            • 2. Check the cable.
          • Table 48 - Alphanumeric Error Codes
      • Recovery Messages
        • Table 49 - Recover Messages
    • Notes:
• App B - Event Log Descriptions
  • 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
      • Before You Begin
    • 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
        • Replacing a 1756-EWEB Module
        • Updating Communication Settings
      • 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.
        • a. Launch ControlFLASH software and click Next.
        • b. Select the Ethernet module catalog number and click Next.
        • c. Browse to the module and select it.
        • d. Click OK.
        • e. Select the firmware revision to upgrade to and click Next.
        • f. Click Finish.
      • 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
        • 1. Launch RSLinx Classic software.
        • 2. Click RSWho.
        • 3. Right-click your redundancy module and choose Module Configuration.
        • 4. Right-click the title bar and select About.
      • 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
        • 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.
      • 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.
          • Table 50 - Controller Compatibility
        • 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).
• 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
      • Table 51 - Components Available for Use in a Redundant Chassis Pair
    • Add an Identical Chassis
    • Upgrade to Enhanced Redundancy Firmware
    • Update the Controller Revision and Download the Project
    • Notes:
• App E - Redundancy Object Attributes
  • Redundancy Object Attributes
    • Notes:
• App F - Enhanced Redundancy System Checklists
  • Enhanced Redundancy System Checklists
    • Chassis Configuration Checklist
    • Remote I/O Checklist
    • Redundancy Module Checklist
    • ControlLogix Controller Checklist
    • ControlNet Checklist
    • EtherNet/IP Module Checklist
    • Project and Programming Checklist
• App G - Enhanced Redundancy Revision History
  • Enhanced Redundancy Revision History
    • Changes to This Manual
      • Table 52 - History of Changes
    • Notes:
  • Index
    • Notes:
• Back Cover