1 controllogix redundancy. rockwell automation confidential2 main redundancy features optimized for...

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1 POWER Redundancy Module PRI COM OK PR IM POWER Redundancy Module PRI COM OK SY N C C ontrol NET CHA CHB OK A #01 RUN REM PROG Logix5555 TM RUN OK R S232 BAT I/O RUN REM PROG Logix5555TM RUN OK R S 232 BAT I/O C ontrol NET CHA CHB OK A #02 A llen-B radley Q uality A-B A llen-B radley Q uality A-B ControlLogix Redundancy

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Page 1: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

1

POWERRedundancy Module

PRI COM OK

PRIM

POWERRedundancy Module

PRI COM OK

SYNC

ControlNET

CHA CHB OK

A#01

RUN REM PROG

Logix5555TM

RUN

OK

RS232

BAT

I/O

RUN REM PROG

Logix5555TM

RUN

OK

RS232

BAT

I/O

ControlNET

CHA CHB OK

A#02

Allen-BradleyQuality

A-B

Allen-BradleyQuality

A-B ControlLogix Redundancy

Page 2: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

2

Main Redundancy Features

• Optimized for availability of control.• Absolutely no user programming required to implement.• Bumpless switchover guaranteed for any outputs controlled by logic in

the highest priority task.• Switchover within approximately 100 msec.• Works with standard Logix5555 controllers and ControlNet Bridges

(Series D or higher).• Switchovers are transparent to any devices networked to the redundant

controller chassis.

• Transparent cross-load of programs from primary to secondary

controllers.

• On-line workstation configuration/commands/edits to primary are

automatically forwarded to secondary.

• User can choose to cancel or resume ‘test edits’ at switchover.

Page 3: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

3

Building a Typical Redundant System

Allen-BradleyA-BQuality

ControlNET

CHA CHB OK

A#01

Redundancy Module

PRI COM OK

PRIM

RUN REM PROG

Logix5555™

RUN

OK

RS232

BAT

I/O 2. Add 1 or more Logix5555 processors.3. Add 1 or more ControlNet Bridges (Series D).4. Add 1 System Redundancy Module.5. Set up an identical second controller chassis.6. Cable the SRMs together.7. Add I/O, operator interfaces, and so forth to the

ControlNet network(s).

1. Start with a standard ControlLogix chassis.

Allen-BradleyA-BQuality

ControlNET

CHA CHB OK

A#01

Redundancy Module

PRI COM OK

PRIM

RUN REM PROG

Logix5555™

RUN

OK

RS232

BAT

I/O

Page 4: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

4

Other Redundant Architecture Considerations

• Only Logix5555’s, ControlNet Bridges, and a single System Redundancy Module can be placed in a redundant controller chassis.– All I/O must be remote from the redundant controller chassis.

– To connect to other networks, bridge through another ControlLogix chassis.

Allen-BradleyA-BQuality

ControlNET

CHA CHB OK

A#01

Redundancy Module

PRI COM OK

PRIM

RUN REM PROG

Logix5555

™RUN

OK

RS232

BAT

I/O

Allen-BradleyA-BQuality

ControlNET

CHA CHB OK

A#01

Redundancy Module

PRI COM OK

PRIM

RUN REM PROG

Logix5555

™RUN

OK

RS232

BAT

I/O ControlNet

Ethernet

Page 5: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

5

Logix5555 Controller• New CPU ASIC

– Provides alternative memory parity encoding method so that higher density commercial memory may be used.

– New memory change detection algorithms for Redundancy.

• New circuitry to support new 1.5, 3.5, and 7.5 Mbyte memory cards.

• Increased Performance– Faster Flash-Memory to increase operating system

performance.– Movement of Floating Point library to RAM for higher

performance (30% faster than L1).

• Hardware changes to support ControlLogix redundancy.

• New Real Time Clock (RTC) chip with increased accuracy.

• In redundancy, data is buffered in the secondary controller, so twice as much data memory space is required.

Page 6: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

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ControlNet allows transparent switchovers• The 1756-CNB Series D has added the necessary

hardware and firmware changes to support ControlLogix redundancy.

• You set the same ControlNet address on the rotary switches of the primary and secondary CNB’s.– The primary CNB will use that address, and the

secondary CNB will automatically use the next higher address.

• On a switchover, the CNB’s automatically swap addresses.– Any external ControlNet devices will simply continue

to communicate with the new primary controller.

– ControlLogix redundancy works transparently with 1756 I/O, Flex I/O, drives, operator interfaces, or any other Rockwell or third-party devices which can communicate to a Logix5555 over ControlNet.

Page 7: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

7

System Redundancy Module

• The 1757-SRM provides the high speed data transfers between the primary and secondary chassis and arbitrates primary/secondary chassis status.

• Two slot module• Only one SRM per chassis needed.

– We will test with up to four Logix5555 processors per chassis.

• A fiber optic cable connects the primary and secondary SRM’s.– 1757-SRC1, SRC3, or SRC10 (1, 3, or 10

meter lengths)

Redundancy Module

PRI COM OK

PRIM

Page 8: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

8

1757-SRM Configuration• The 1757-SRM module will be configured from RSLinx instead of

RSLogix 5000.– Allows one 1757-SRM to support multiple Logix5555 controllers.

– Similar to how DHRIO and ENET modules are configured using RSLinx 2.2.

Page 9: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

9

SRM Dialog Module Info Tab

Chassis_B: Primary with QualifiedSecondary

1757-SRM REDUNDANCY MODULE

Provides identification of the module.

Provides identification of the module.

Provides the general status of the module.

Provides the general status of the module.

Identifies the current

redundancy state of this

chassis. This is visible from

every tab on the dialog.

Identifies the current

redundancy state of this

chassis. This is visible from

every tab on the dialog.

Page 10: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

10

SRM Dialog Configuration Tab

Chassis_B: Primary with QualifiedSecondary

Select when you want a disqualified secondary chassis to automatically attempt synchronization.

• Always• Never• Conditional - Auto-synchronization enabled on

a Synchronize Secondary command and disabled on a Disqualify Secondary command.

Select when you want a disqualified secondary chassis to automatically attempt synchronization.

• Always• Never• Conditional - Auto-synchronization enabled on

a Synchronize Secondary command and disabled on a Disqualify Secondary command.

Lets you specify whether this chassis should be referred to as

Chassis A or Chassis B.

Lets you specify whether this chassis should be referred to as

Chassis A or Chassis B.

Select whether programmed messages from a Logix5555 are

allowed to trigger redundancy

commands (initiate switchover, disqualify

secondary, etc.)

Select whether programmed messages from a Logix5555 are

allowed to trigger redundancy

commands (initiate switchover, disqualify

secondary, etc.)

Set the date and time to be used in the SRM event log.

Set the date and time to be used in the SRM event log.

Page 11: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

11

SRM Dialog Synchronization Tab

Chassis_B: Primary with QualifiedSecondary

1757-SRM REDUNDANCY MODULE

Issues a manual command to attempt to synchronize the

secondary chassis to make it available for

switchover.

Issues a manual command to attempt to synchronize the

secondary chassis to make it available for

switchover.

Issues a manual command to

disqualify the secondary chassis to make it unavailable

for switchover.

Issues a manual command to

disqualify the secondary chassis to make it unavailable

for switchover.

Issues a manual command to switch

control to the secondary chassis. This can be used to test the redundant

system.

Issues a manual command to switch

control to the secondary chassis. This can be used to test the redundant

system.

Issues a manual command allowing a

disqualified secondary chassis with no partner to

take control.

Issues a manual command allowing a

disqualified secondary chassis with no partner to

take control.

Shows the result of the last four

synchronization attempts of the

redundant system.

Shows the result of the last four

synchronization attempts of the

redundant system.

Page 12: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

12

SRM Dialog Chassis Profile Tab

Chassis_B: Primary with QualifiedSecondary

1757-SRM REDUNDANCY MODULE

Shows the progress of synchronization

in percent.

Shows the progress of synchronization

in percent.

Shows the secondary’s

readiness to take control.

Shows the secondary’s

readiness to take control.

Shows the state of the modules

(startup, faulted, etc).

Shows the state of the modules

(startup, faulted, etc).

Shows the compatibility between the primary and

secondary module.

Shows the compatibility between the primary and

secondary module.

• Shows the current state of all the modules in this redundant controller chassis.

Page 13: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

13

SRM Dialog Event Log Tab

• This dialog shows the history of the past 10 events.• Events that are logged include synchronizations, switchovers, etc.• This information is stored on the SRM module.

1757-SRM REDUNDANCY MODULE

Chassis_B: Primary with QualifiedSecondary

Page 14: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

14

No programming required

• A primary Logix5555 automatically determines what data changes during its scan and automatically sends that data to its secondary Logix5555. You don’t have to program messages or even specify certain data areas to transfer. It all just happens automatically.

You just select a single checkbox on the

controller properties dialog to enable

redundancy.

You just select a single checkbox on the

controller properties dialog to enable

redundancy.

Page 15: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

15

Other Controller Properties Options

This enables

redundancy.

This enables

redundancy.

Lets you specify how much of the unused memory will be

allocated for adding data online versus adding program online.

Lets you specify how much of the unused memory will be

allocated for adding data online versus adding program online.

Allows you to specify whether you want test edits to remain in effect after a switchover.

This is useful for online edit changes.

Allows you to specify whether you want test edits to remain in effect after a switchover.

This is useful for online edit changes.

Here you can see the status of this controller chassis and this

controller.

Here you can see the status of this controller chassis and this

controller.

Here you can see the status of this controller’s redundant partner.

Here you can see the status of this controller’s redundant partner.

Page 16: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

16

Automatic cross-loading of programs

• You only have to download your program to the primary controller. The system will automatically cross-load the primary’s program to the secondary controller.

Allen-BradleyA-BQuality

ControlNET

CHA CHB OK

A#01

Redundancy Module

PRI COM OK

PRIM

RUN REM PROG

Logix5555™

RUN

OK

RS232

BAT

I/O

Allen-BradleyA-BQuality

ControlNET

CHA CHB OK

A#01

Redundancy Module

PRI COM OK

PRIM

RUN REM PROG

Logix5555™

RUN

OK

RS232

BAT

I/O

Page 17: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

17

Bumpless Switchovers

• The secondary controller is synchronized with the primary to provide a bumpless switchover for any outputs controlled by logic in the highest priority task:– Primary notifies secondary when user tasks start.

– Primary notifies secondary when programs complete & provide a complete data ‘snapshot’.

• Secondary doesn’t execute programs, but follows along, pending at each program start.

• Incomplete transfers are ‘quarantined’ on secondary until complete.

– At switchover, the new primary rolls back to the beginning of currently executing programs using ‘last good’ data snapshot.

Page 18: 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for availability of control. Absolutely no user programming

Rockwell Automation Confidential

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ControlLogix Redundant Power Supply1756-PA75R / -PB75RPower Supplies• 85 - 265 VAC and 19 - 32 VDC

Versions• Panel mount (1756-A4 footprint -

6.9" H x 5.7" W x 5.4" D)• Px75 equivalent capacity

1756-CPR Cables• 3 foot max length • Pin-outs provided if you want to

make shorter cables

1756-PSCAChassis Adapter Module• Passive device funnels power

to backplane• Series B chassis only

Failure Annunciation• Normally Open solid state relay on each supply• Wire to any input module