ControlLogix Redundancy Enhanced

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Overview of the Rockwell PLC with Redundancy Enhanced features.

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<ul><li><p>ControlLogix Enhanced Redundancy SystemCatalog Numbers 1756-RM, 1756-RMXT, 1756-RM2, 1756-RM2XT</p><p>User Manual</p></li><li><p>Important User Information</p><p>Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.</p><p>In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.</p><p>The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.</p><p>No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.</p><p>Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.</p><p>Throughout this manual, when necessary, we use notes to make you aware of safety considerations.</p><p>Allen-Bradley, ControlFLASH, ControlLogix, FactoryTalk, PanelView, PhaseManager, Rockwell Software, Rockwell Automation, RSLinx, RSLogix, RSNetWorx, VersaView, RSView32, Logix5000, ControlLogix-XT, Integrated Architecture, Stratix 8000, PowerFlex, POINT I/O are trademarks of Rockwell Automation, Inc.</p><p>Trademarks not belonging to Rockwell Automation are property of their respective companies.</p><p>WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.</p><p>ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.</p><p>SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.</p><p>BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.</p><p>IMPORTANT Identifies information that is critical for successful application and understanding of the product.</p></li><li><p>Summary of Changes</p><p>This publication contains new and updated information. Changes throughout this revision are marked by change bars, as shown to the right of this paragraph.</p><p>New and Updated Information</p><p>This table contains the changes made to this publication revision.</p><p>Table 1 - New and Updated Information</p><p>Topic Page</p><p>This publication includes the addition of the 1756-RM2/A and 1756-RM2XT modules. 1756-RM2/A or 1756-RM2XT modules can only be used with other 1756-RM2/A or 1756-RM2XT modules. You cannot mix 1756-RM2/A and 1756-RM2XT modules with 1756-RM/A, 1756-RM/B or 1756-RMXT modules.</p><p>References throughout the manual to specific redundancy module catalog numbers have been replaced with redundancy module. </p><p>This manual includes SIL2 application information. 13</p><p>Features of enhanced redundancy system using 1756-RM2/A module. 16</p><p>Replace 1756-RM/B redundancy modules with 1756-RM2/A redundancy modules without initiating a switchover.Fiber channels will experience a delay during a switchover, but will remain synched.</p><p>20</p><p>1756-RM2/A restrictions. 22</p><p>Added 1756-RM2/A and 1756-RM2XT information; important revision information changes for the 1756-RM2/A and 1756-RM2XT modules.</p><p>24</p><p>The revision has been updated wherever the 1756-L7x controller appears in this manual to 19.053.</p><p>27</p><p>Added new firmware bundles 20.054_kit1, 19.053_kit1, and 19.081_kit1. 49</p><p>Use newest version of RMCT when using 1756-RM2/A redundancy module. 54</p><p>Added the 1756-RM2/A and 1756-RM2XT modules and installation requirements. 57</p><p>Added the statement: 1756-RM2/A or 1756-RM2XT modules can only be used with other 1756-RM2/A or 1756-RM2XT modules. You cannot mix 1756-RM2/A and 1756-RM2XT modules with 1756-RM/A, 1756-RM/B or 1756-RMXT modules.</p><p>57</p><p>Environment and Enclosure change. 58</p><p>Small form-factor pluggable warning. 59</p><p>Added new 1756-RM2/A and 1756-RM2XT module graphics. 61</p><p>Added installation instructions. 62</p><p>Added information about connecting fiber-optic cable to redundancy channels and using redundant fiber cabling.</p><p>64</p><p>Updated fiber-optic cable information for new redundancy modules. 67</p><p>Updated the graphics for the redundant fiber-optic cable. 68</p><p>Updated the graphics for the redundant fiber-optic cable. 69</p><p>Using dual fiber ports with the 1756-RM2 redundancy modules 138</p><p>Crossload times when using a 1756-L7x and a 1756-RM2/A redundancy module. 151</p><p>Using a 1756-L7x controller with a 1756-RM2/A redundancy module. 152 </p><p>Status indicators for 1756-RM2/A and 1756-RM2XT. 200</p><p>1756-RM2/A and 1756-RM2XT status indicators. 227</p><p>CH1 status indicator. 229</p><p>CH2 status indicator. 229Rockwell Automation Publication 1756-UM535D-EN-P - November 2012 3</p></li><li><p>Summary of ChangesSFP error message. 230</p><p>Added missing Module Status Display descriptions for the 1756-RM/A and 1756-RM/B modules.</p><p>231</p><p>Replace 1756-RM/B redundancy modules with 1756-RM2/A redundancy modules without initiating a switchover.</p><p>264</p><p>Table 1 - New and Updated Information</p><p>Topic Page4 Rockwell Automation Publication 1756-UM535D-EN-P - November 2012</p></li><li><p>Table of Contents</p><p>Preface Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13</p><p>Chapter 1About Enhanced Redundancy Systems</p><p>Features of the ControlLogix Enhanced Redundancy System . . . . . . . . 16Enhanced Redundancy System Components . . . . . . . . . . . . . . . . . . . . . . . 17</p><p>I/O Modules in Enhanced Redundancy Systems . . . . . . . . . . . . . . . . 18Enhanced Redundancy System Operations . . . . . . . . . . . . . . . . . . . . . . . . . 19</p><p>System Qualification and Synchronization . . . . . . . . . . . . . . . . . . . . . 19Switchovers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20</p><p>Restrictions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22</p><p>Chapter 2Design an Enhanced Redundancy System</p><p>Components of an Enhanced Redundancy System . . . . . . . . . . . . . . . . . . 24Redundant Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Controllers in Redundant Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Redundancy Modules in Redundant Chassis. . . . . . . . . . . . . . . . . . . . 31Communication Modules in Redundant Chassis . . . . . . . . . . . . . . . . 32Power Supplies and Redundant Power Supplies in Enhanced Redundancy Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34</p><p>EtherNet/IP Networks with Redundant Systems . . . . . . . . . . . . . . . . . . . 35EtherNet/IP Network Features in an Enhanced Redundancy System, Revision 19.052 or Later . . . . . . . . . . . . . . . . . . 35IP Address Swapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Unicast Functionality. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Possible Communication Delays on EtherNet/IP Networks . . . . . 36</p><p>ControlNet Networks with Redundant Systems . . . . . . . . . . . . . . . . . . . . 38ControlNet Network Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Redundant ControlNet Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41</p><p>Other Communication Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42I/O Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44</p><p>1715 Redundant I/O Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Using HMI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46</p><p>HMI Connected via an EtherNet/IP Network. . . . . . . . . . . . . . . . . . 46HMI Connected via a ControlNet Network. . . . . . . . . . . . . . . . . . . . 47</p><p>Firmware Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Software Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49</p><p>Required Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Optional Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50</p><p>Chapter 3Install the Enhanced Redundancy System</p><p>Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51Enhanced Redundancy System Quick Start . . . . . . . . . . . . . . . . . . . . . 51</p><p>Install an Enhanced Redundancy System . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Step 1: Install the Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Rockwell Automation Publication 1756-UM535D-EN-P - November 2012 5</p></li><li><p>Table of ContentsInstall the Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Add the EDS Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54</p><p>Step 2: Install the Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Install the First Chassis and its Components . . . . . . . . . . . . . . . . . . . . 54Install the Chassis and Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Install the Communication Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Install a Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Install the Redundancy Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57Environment and Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Prevent Electrostatic Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Removal and Insertion Under Power (RIUP) . . . . . . . . . . . . . . . . . . . 58European Hazardous Location Approval . . . . . . . . . . . . . . . . . . . . . 58Safety-related Programmable Electronic Systems . . . . . . . . . . . . . . . . 59Optical Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Small Form-factor Pluggable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59North American Hazardous Location Approval . . . . . . . . . . . . . . . . . 60Laser Radiation Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Install the Second Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63</p><p>Step 3: Connect the Redundancy Modules via a Fiber-optic Cable . . . . 63Connect the Fiber-optic Communication Cable to Redundant Channels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Connect the Fiber-optic Communication Cable to Single Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Fiber-optic Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67</p><p>Step 4: Update Redundant Chassis Firmware . . . . . . . . . . . . . . . . . . . . . . . 67Upgrade the Firmware in the First Chassis . . . . . . . . . . . . . . . . . . . . . . 68Upgrade the Firmware in the Second Chassis . . . . . . . . . . . . . . . . . . . 71</p><p>Step 5: Designate the Primary and Secondary Chassis. . . . . . . . . . . . . . . . 71After Designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Conversion from a Nonredundant to a Redundant System . . . . . . . 73Qualification Status via the RMCT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Reset the Redundancy Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75Remove or Replace the Redundancy Module . . . . . . . . . . . . . . . . . . . . 75</p><p>Chapter 4Configure the EtherNet/IP Network Requested Packet Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77</p><p>CPU Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Use IP Address Swapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77</p><p>Static versus Dynamic IP Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Reset the IP Address for an EtherNet/IP Communication Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80</p><p>Use CIP Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Use Produce/Consume Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84Configure EtherNet/IP Communication Modules in a </p><p>Redundant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Before You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 856 Rockwell Automation Publication 1756-UM535D-EN-P - November 2012</p></li><li><p>Table of ContentsOptions for Setting the IP Addresses of EtherNet/IP Communication Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Half/Full Duplex Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86</p><p>Use An Enhanced Redundancy System in a Device-level Ring Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87</p><p>Chapter 5Configure the ControlNet Network Produce/Consume Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93</p><p>Network Update Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95NUTs with Multiple ControlNet Networks . . . . . . . . . . . . . . . . . . . . 95</p><p>Use a Scheduled or Unscheduled Network . . . . . . . . . . . . . . . . . . . . . . . . . 97Use a Scheduled Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Use an Unsc...</p></li></ul>