Introduction to ControlLogix Redundancy Customer Presentation.pptx

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Introduction to ControlLogix Redundancy
February 2018

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Agenda
Monitoring Redundancy
Redundancy Switchover
How to Enable and Configure
Hardware and Restrictions
Introduction to Redundancy

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 Dual Chassis Design
 Full Redundancy
 Both Chassis match
 Transparent
 Primary/Secondary Chassis
 IP Address Swap
 ControlNet Node Swap
 Easy to use
 No special code
 Automatic Crossloading of data
and logic
 Treat as one chassis
 Uses Standard 1756 hardware
 Up To:
 2 Controllers
 7 Communications Modules
ControlLogix® Redundancy

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Introduction ControlLogix Redundancy
 ControlLogix Redundancy consist of:
 2 separate ControlLogix chassis with identical hardware and firmware
configuration
 Standard ControlLogix hardware is used
 Each chassis contains a redundancy module
 Redundancy modules are connected by a fiber link
 Redundant fiber links with the 1756-RM2
 Redundancy switches system control from one chassis to the other
 Chassis can only contain processor(s) and communications modules
 No I/O can reside in the redundancy chassis
 All I/O is remote I/O
ControlLogix Redundancy uses standard ControlLogix hardware
with the addition of the redundancy modules

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 Operation Basics
 Application in Primary is automatically
crossloaded into the Secondary processor
 Data changes are sent to secondary at the end
of each program
 On-Line application changes are also sent from
the primary to the secondary
 This keeps Primary and Secondary always
synchronized
 System is “Floating Master” type. Each chassis
is capable of being Primary
5
Secondary Chassis
Primary Chassis
1756-RM2

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Example ControlLogix Redundancy configuration with
ControlNet remote I/O

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 All I/O in a redundancy system is remote I/O
 The switchover between chassis is bumpless for all class1 connections
 I/O
 Producer/Consumer tags (Ethernet)
 Connections that are Class 1 are not dropped during the switchover
 The chassis currently controlling the process is the Primary chassis
 The other chassis is the Secondary Chassis
 Chassis are also labeled as: Chassis A and Chassis B. These label
the physical chassis. These names to not change on switchover
Redundancy provides a bumpless switchover to a second
ControlLogix chassis.
ControlLogix Redundancy switchovers are bumpless

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 The redundancy module monitors the primary chassis for module faults.
 A module faults triggers a switchover to the other chassis
 A switchover moves system control from one chassis to the other
 All communications is switchover over at the same time
 Control of all I/O is moved to the new Primary chassis
 HMI communication is moved to the new Primary chassis
 The new Primary continues running the application at the end of last
synchronization point.
 The application continues to run in the New Primary chassis where it left off
A redundancy switchover moves system control to the secondary
ControlLogix chassis.
A switchover moves system control from one chassis to the
other.

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 The Redundancy Module synchronizes the 2 redundancy chassis
 The application code is automatically crossloaded from the Primary controller to the
Secondary controller
 All on-line changes are crossloaded while the process is running
 We do not download an application to the secondary controller, it is
crossloaded by the redundancy module.
 Tag values are automatically crossloaded from the Primary controller to the
Secondary controller while the program is running
 We do not need to configure crossloading
 During a switchover, the new primary is ready to run the process with the
crossloaded data.
The Redundancy module synchronizes the chassis

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 Address swapping keeps the Primary chassis at the same IP Address and
Node number
 The secondary always has an IP Address and Node number of 1 +
the primaries address
 This always points the HMI, programming terminal and all other
devices at the primary chassis
 We do not need to communicate to the secondary chassis
 You should not communicate to the secondary chassis
 Must account for the extra IP Address and Node number in your network
design.
 You will see the secondary's modules in RSLinx
Address swapping keeps the Primary chassis always at the
same IP address and node number

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 The entire ControlLogix chassis is duplicate by another chassis
 This keeps the process running during system faults:
 Chassis power supply faults
 Redundant power supplies are supported.
 Communications Module fault – hardware or firmware
 This gives us redundant communications modules
 DLR is supported
 Controller fault – hardware, firmware or application code major fault
 Major faults include: Array index out of range, watchdog
 No single point of failure can take the system down
ControlLogix Redundancy is design for High Availability
No single point of failure can take a ControlLogix Redundancy
system down

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 Upgrades can be made while the process is running
 A locked update switchover allows ControlLogix Redundancy to switchover to a
chassis with upgraded firmware and/or hardware.
 Hardware can be changed and upgraded while the system is running
 Firmware updates can be made while the system is running
 Primary and Secondary controllers are always automatically synchronized
 No data is lost during a switchover
 I/O stays connected during a switchover (bumpless switchover)
ControlLogix Redundancy is design for High Availability
Firmware and hardware upgrades can be made while the
process is running.

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Agenda

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 The firmware bundle contains:
 All of the firmware for the all of the modules that can be used in the
redundancy chassis
 Release Notes for the firmware bundle
 List of supported modules
 Firmware version included in the bundle for all supported modules
 List of corrected anomalies, known anomalies, restrictions
 Detailed system upgrade instructions
 A new version of the Redundancy Module Configuration Tool (RMCT)
ControlLogix Redundancy is released with a firmware bundle
Redundancy requires all modules in the redundancy chassis to
use the redundancy firmware bundle

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Latest firmware bundle release is V30.051
For this presentation we are only discussing the latest hardware and
firmware for ControlLogix Redundancy
 1756-RM2 Module
 1756-RM and 1757-SRM modules are no longer being sold
 1756-RM2 is the only supported Redundancy Module in V24.05x and beyond.
 1756-EN2T / 1756-EN2TR / 1756-EN2F
 Supported Ethernet modules in the redundancy chassis
 1756-CN2 / 1756-CN2R
 Supported ControlNet modules in the redundancy chassis
 1756-L7x Controllers
 1756-L6x controllers are still supported, but you get much more performance with
the 1756-L7x. And Double Data Rate on the backplane (DDR)
 1756-L7x is the only supported controller type in V24.05x and beyond

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 Ethernet I/O connections must be Multicast
 This also means all Ethernet I/O must be on the same subnet
 Produced tags can be Unicast or Multicast
 Consumed tags must be Multicast
 Event tasks are not supported
 Motion control is not supported
 All tasks must be enabled
 Scan time will increase approximately 15%-35% while redundancy is synchronized
 Scan time will decrease when redundancy is not synchronized
 Task Watchdog time will need to be set according to guidelines found in the users manual
 In most cases the watchdog time will need to be increased over what is normally used
The designer of a ControlLogix Redundancy system will need to
review the system restrictions before designing the system
ControlLogix Redundancy has a few key restriction from a non-
redundant system

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Agenda

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 Configuration of ControlLogix
Redundancy requires checking
a checkbox in the controller
properties of the application
code.
 That is the only
configuration required in
the application code!
 The checkbox enables
redundancy
ControlLogix Redundancy requires only a checkbox to turn the
redundancy functionality On

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 ControlLogix Redundancy Configuration Check List:
 Review the Redundancy Bundle release notes:
 Review known limitations and restrictions
 Corrected anomalies, Known anomalies
 Install the firmware bundle on all modules in both redundancy chassis
 Install the Redundancy Module Configuration Tool (RMCT) on the
engineering workstation
 Configure on chassis as A and the other as B
 Set the time on the 1756-RM2 clock
 Check the Enable Redundancy checkbox in the application
 Download the application to the Primary Chassis Controller
Redundancy firmware bundle release notes should be reviewed
before installing or upgrading a system.

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Agenda

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 Current Redundancy state can be monitored on the 1756-RM2 LED
display
 PRIM – Primary chassis, controlling the process
 SYNC – Secondary chassis, synchronized
 DISQ – Secondary chassis, not synchronized
 QFNG – Secondary chassis, in the process of synchronizing
 The RM2 LED display will let you quickly find the Primary redundancy
chassis.
The RM2 LED display gives you the current redundancy status

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 Primary Chassis
 Both fiber channels OK
 Active fiber channel LED will blink
 RM2 Module OK
 Synchronized Secondary
 Both fiber channels OK
 Active fiber channel LED will blink
 RM2 Module OK
 Primary Chassis
 Both fiber channels faulted
 Secondary maybe be powered off
 RM2 Module OK

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 ControlLogix Redundancy Modes:
 You can monitor which mode is active from the RMCT and inside of the application logic using a
GSV instruction pointed to the redundancy module object
 These are the names of the statuses used in the RMCT and the GSV
 Statuses in the Primary 1756-RM2:
 Primary with Qualified Secondary (PwQS)
 System is synchronized and secondary is ready to take over control as needed
 Primary with Disqualified Secondary (PwDS)
 Primary is controlling the system. The secondary has a fault or is in the process of qualification
 Primary with No Secondary (PwNS)
 Primary is controlling the system. The primary cannot see the secondary from the fiber link between
the redundancy modules. Secondary may have lost power
 Statuses in the Secondary 1756-RM2:
 Qualified Secondary (QS)
 Secondary is synchronized and ready to take over control as needed
 Disqualified Secondary with Primary (DQSwP)
 Secondary has not yet synchronized or has a fault present that is preventing synchronization
 Disqualified Secondary with No Primary (DQSwN)
 The secondary cannot see the primary from the fiber link between the redundancy modules

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 ControlLogix Redundancy switchovers occur due to:
 Power Loss in Primary chassis
 Module fault in Primary chassis
 Controller fault in Primary chassis
 Chassis backplane failure
 Complete loss of communications on a communication module in the
Primary chassis
 Ethernet Link Loss
 ControlNet goes Lonely
 Manual switchover, from:
 Controller
 HMI
 Redundancy Module Configuration Tool (RMCT) in RSLinx Classis
Faults and loss of power trigger a redundancy switchover

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 ControlLogix Redundancy does not switchover due to:
 Remote I/O fault
 Loss of communication to any remote I/O chassis or module
 Module fault in a remote I/O connection
 Communications fault
 Communications must be a lost completely at the module to trigger a switchover.
Such as a broken wire or power off at the switch
 Loss of connection to Secondary Chassis
 Secondary chassis will Disqualify, but no switchover
 Fault in secondary will Disqualify, but no switchover
 Controller going into Program Mode
 Downloading a new application to the controller
Faults and loss of power at the primary redundancy chassis
trigger a redundancy switchover

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Agenda

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Monitoring Redundancy Status with the RMCT
Opening the RMCT from RSLinx Classic. The redundancy module was
selected and then a right click to Module Configuration
Right mouse
Click here
Select
Module Configuration

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Opening tab of the RMCT

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Configuration – Turn off Synchronization, define chassis ID, update
redundancy module log time and date (not sync’d with Logix)

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Synchronization – history of recent synchronization attempts. Ability to
manually synchronize, disqualify, and switchover

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Synchronization Status, Displays active % complete while the system
is synchronizing

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Event Log – Advanced redundancy debug logging information. You
may need to export this and send to tech support if you a question on
a switchover or fault

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System Update – used for the Locked update procedure to update
firmware and hardware on a running redundancy system

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System Event History – Brief history of redundancy events. Designed to be a readable
event history. Much easier to read then the event log. The Data and Time are from the
redundancy module clock, not the controllers clock

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Important Knowledgebase Articles
 457489 - Logix Redundancy Book of Knowledge
 55721 - Extracting Log Files from 1756-RM2, 1756-RM or 1757-SRM
 64856 - Required information when escalating a case to Commercial Engineering
 24140 - Reasons for a CLX redundancy switchover
 106085 - How to Programmatically Initiate a Switchover with ControlLogix Redundancy
 518071 - Application update required displayed on 1756-RM2
 117001 - Control Logix Redundancy 1756-RM2/RM and 1757-SRM fiber cable distances and specs
 484206 - CIP SYNC restrictions when used with redundancy systems
 578295 - Upgrading a Running ControlLogix Redundancy system to 1756-EN2T/D or 1756-EN2TR/C
 26789 - GSV REDUNDANCY Object
 61633 - Can a ControlLogix Redundancy type 12 code 32 fault be cleared without going online using RSLogix 5000
 24419 - Type 12 Redundancy Fault and Code 32 Disqualified Secondary Became Primary
 57158 - How programmatically set SRM Time in Redundancy System Version 16 or higher
 63409 - Using the Redundancy System Update (RSU) feature to re download the application
 68509 - FactoryTalk Alarm and Events (FTAE) - Enhanced ControlLogix Redundancy
 576781 - Logix Redundancy Upgrading Ethernet Modules With Rotary Switches
 565372 - How to update modules in an enhanced redundant system
 457490 Red Supports Unicast Produced Tags
 449304 - Logix Redundancy User Selectable Switchover on Ethernet Network Loss
 119660 - Logix Redundancy RM/SRM Log Error - Partner Not on Same Link

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Introduction to ControlLogix Redundancy Customer Presentation.pptx

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