ControlLogix®

Redundancy
System

User Manual
Important User Information Because of the variety of uses for the products described in this
publication, those responsible for the application and use of these
products must satisfy themselves that all necessary steps have been
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Any illustrations, charts, sample programs, and layout examples
shown in this publication are intended solely for purposes of
example. Since there are many variables and requirements associated
with any particular installation, Rockwell Automation does not assume
responsibility or liability (to include intellectual property liability) for
actual use based upon the examples shown in this publication.
Allen-Bradley publication SGI-1.1, Safety Guidelines for the
Application, Installation and Maintenance of Solid-State Control
(available from your local Rockwell Automation office), describes
some important differences between solid-state equipment and
electromechanical devices that should be taken into consideration
when applying products such as those described in this publication.
Reproduction of the contents of this copyrighted publication, in whole
or part, without written permission of Rockwell Automation, is
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Throughout this publication, notes may be used to make you aware of
safety considerations. The following annotations and their
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potential hazard:

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.

Identifies information about practices or

ATTENTION
circumstances that can lead to personal injury or
death, property damage, or economic loss.

!
IMPORTANT Identifies information that is critical for successful
application and understanding of the product.
 Summary of Changes

Introduction This release of this document contains new and updated information.
To find new and updated information, look for change bars, as shown
next to this paragraph.

Updated Information The document contains the following changes:

This new or updated information: See:

New chapter that gives an overview of the ControlLogix® redundancy system, including basic operation, Chapter 1
switchover, synchronization, crossloading, handling of ControlNet™ addresses, and quick start checklists
Expanded guidelines on how to lay-out a system Chapter 2
Recommendations for the number of ControlNet networks
Recommendations for the number of PanelView terminals
Restrictions on the networks for I/O
Optional components for a redundancy system
Restrictions on the use of a network access port (NAP) Chapter 3
Download a project
Schedule a ControlNet network
When to retain test edits Chapter 4
How to estimate scan time
Tips to minimize scan time
Troubleshoot a failure to synchronize Chapter 5
Update keeper signatures
Tips to optimize communication performance
Interpret the 4-character display of a CNB module
Export SRM events to Microsoft® Excel
Get system values (reorganized to make it easier to use)
Store or load a project using nonvolatile memory
Bill of materials (moved to an appendix) Appendix A
Convert an non-redundant system to a redundant system (moved to an appendix) Appendix B
Glossary of common terms Glossary

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Summary of Changes 2

Notes:

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 Preface

Purpose of this Manual This manual guides the design, development, and implementation of a
redundancy system for a ControlLogix® controller.

Who Should Use this This manual is intended for those individuals who design and develop
applications that use ControlLogix controllers, such as:
Manual
• software engineers
• control engineers
• application engineers
• instrumentation technicians

When to Use This Manual Use this manual throughout the life-cycle of a redundancy system:

• design
• installation
• configuration
• programming
• testing
• maintenance and troubleshooting

How to Use this Manual This manual is divided into the basic tasks that you perform during
the design, development, and implementation of a ControlLogix
redundancy system.

• Each chapter covers a task.

• The tasks are organized in the sequence that you will typically
perform them.

As you use this manual, you will see some text that is formatted
differently from the rest of the text:

Text that is: Identifies: For example: Means:

Italic the actual name of an item that you Right-click User-Defined … Right-click on the item that is named
see on your screen or in an example User-Defined.
courier information that you must supply Right-click You must identify the specific program in
based on your application (a name_of_program … your application. Typically, it is a name or
variable) variable that you have defined.
enclosed in brackets a keyboard key Press [Enter]. Press the Enter key.

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Preface 2

Notes:

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 Table of Contents

Chapter 1
ControlLogix® Redundancy Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Overview Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Switchover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Crossloading Tag Values . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
ControlNet Node Addresses . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Quick Start Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
System Lay-Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Redundant Chassis Configuration . . . . . . . . . . . . . . . . . 1-8
RSLogix™ 5000 Project . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Chapter 2
Design the System How to Use this Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Lay Out the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Place the I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Add Additional Redundant Components. . . . . . . . . . . . . . . 2-5
Redundant ControlNet Media . . . . . . . . . . . . . . . . . . . . 2-5
Redundant Power Supplies. . . . . . . . . . . . . . . . . . . . . . 2-6
Check Connection Requirements . . . . . . . . . . . . . . . . . . . . 2-6
Assign ControlNet Addresses . . . . . . . . . . . . . . . . . . . . . . . 2-7
Select a Network Update Time . . . . . . . . . . . . . . . . . . . . . 2-9
Estimate the Switchover Time . . . . . . . . . . . . . . . . . . . . . . 2-11

Chapter 3
Install the System When to Use this Chapter . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
How to Use this Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Preliminary Information. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Install the Chassis for the Controllers . . . . . . . . . . . . . . . . . 3-4
Install Modules in the First Redundant Chassis . . . . . . . . . . 3-5
Install Modules in the Second Redundant Chassis . . . . . . . . 3-7
Install the Remote Chassis or Rails . . . . . . . . . . . . . . . . . . . 3-8
Flash the Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Synchronize the Controllers . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Set the Auto-Synchronization Option to Always. . . . . . . 3-10
Synchronize the Controllers . . . . . . . . . . . . . . . . . . . . . 3-11
Download the Project to the Primary Controller . . . . . . . . . 3-12
Schedule the Networks . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Schedule a New Network . . . . . . . . . . . . . . . . . . . . . . . 3-13
Update the Schedule of an Existing Network. . . . . . . . . 3-15
Check the Keepers. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Save the Project for Each Controller . . . . . . . . . . . . . . . 3-16
Test the Switchover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Make Sure the Auto-Synchronization Option = Always . 3-17
Initiate a Switchover. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

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Make Sure the Controllers are Synchronized . . . . . . . . . 3-18

Chapter 4
Configure and Program the When to Use this Chapter . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Controller How to Use this Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Configure the Project for the Controllers . . . . . . . . . . . . . . 4-2
Determine When to Retain Test Edits . . . . . . . . . . . . . . 4-2
Determine How to Reserve Memory . . . . . . . . . . . . . . . 4-3
Configure a Controller for Redundancy . . . . . . . . . . . . . 4-4
Configure Communications . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Configure I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Configure Produced Tags . . . . . . . . . . . . . . . . . . . . . . 4-7
Configure Message (MSG) Instructions . . . . . . . . . . . . . 4-8
Configure Tags for an HMI . . . . . . . . . . . . . . . . . . . . . . 4-8
Estimate the Scan Time of a Program . . . . . . . . . . . . . . . . . 4-9
Minimize Scan Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Use a Few Large Programs . . . . . . . . . . . . . . . . . . . . . . 4-10
Minimize the Use of SINT or INT tags. . . . . . . . . . . . . . 4-10
Use Arrays and User-Defined Data Types . . . . . . . . . . . 4-11
Pack Data into Arrays. . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Execute Instructions Only When Required . . . . . . . . . . 4-13
Maintain the Integrity of Your Data During a Switchover . . 4-15
Look for Array Shift Instructions . . . . . . . . . . . . . . . . . . 4-17
Look for Logic That is Scan-Dependant. . . . . . . . . . . . . 4-18
Take Preventative Actions . . . . . . . . . . . . . . . . . . . . . . 4-19
Set the Task Watchdog Times . . . . . . . . . . . . . . . . . . . . . . 4-20
Estimate a Watchdog Time . . . . . . . . . . . . . . . . . . . . . . 4-20
Set the Watchdog Time for a Task . . . . . . . . . . . . . . . . 4-21
Determine the Scan Time of a Task . . . . . . . . . . . . . . . 4-22

Chapter 5
Maintain and Troubleshoot the When to Use this Chapter . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
System How to Use this Chapter . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Determine the Cause of a Switchover. . . . . . . . . . . . . . . . . 5-2
Troubleshoot a Failure to Synchronize . . . . . . . . . . . . . . . . 5-3
Update a Keeper Signature. . . . . . . . . . . . . . . . . . . . . . 5-4
Check the Recent Synchronization Attempts . . . . . . . . . 5-5
Manually Synchronize the Controllers . . . . . . . . . . . . . . . . 5-6
Optimize Communication . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Choose a Greater System Overhead Time Slice . . . . . . . 5-8
Enter a System Overhead Time Slice. . . . . . . . . . . . . . . 5-9
Make All Your Tasks Periodic. . . . . . . . . . . . . . . . . . . . 5-10
Adjust CNB Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Use RSLinx Software . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Look at the Four Character Display. . . . . . . . . . . . . . . . 5-13

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 Table of Contents 3

Send a Message to the CNB Module . . . . . . . . . . . . . . . 5-14

Export the SRM Event Log to Microsoft® Excel. . . . . . . . . . 5-15
Export Events to a CSV File . . . . . . . . . . . . . . . . . . . . . 5-15
Open and Format the CSV File . . . . . . . . . . . . . . . . . . . 5-17
Configure the Auto-Synchronization Option . . . . . . . . . . . . 5-18
Choose an Auto-Synchronization Option. . . . . . . . . . . . 5-18
Configure the Auto-Synchronization Option . . . . . . . . . 5-18
Get System Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Send a Message to an SRM Module . . . . . . . . . . . . . . . . . . 5-24
Configure the 1757-SRM Module. . . . . . . . . . . . . . . . . . 5-25
Enter the Message Instruction . . . . . . . . . . . . . . . . . . . . 5-26
Configure the Message Instruction . . . . . . . . . . . . . . . . 5-27
Store or Load a Project Using Nonvolatile Memory . . . . . . . 5-30
Update a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31
Disqualify the Secondary Chassis . . . . . . . . . . . . . . . . . 5-31
Upgrade the Required Firmware of the Secondary Chassis . .
5-32
Make the Secondary Controller the New Primary Controller.
5-33
Upgrade the Other Redundant Chassis . . . . . . . . . . . . . 5-33
Change the Auto-Synchronization Option to ALWAYS . . 5-34

Appendix A
Develop the Bill of Materials Redundant Controller Chassis . . . . . . . . . . . . . . . . . . . . . . A-1
Additional Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Appendix B
Convert an Existing System to Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Redundancy Convert Local Modules to Remote Modules . . . . . . . . . . . . B-1
Re-Configure the Local I/O Modules . . . . . . . . . . . . . . . B-2
Replace Local I/O Tags . . . . . . . . . . . . . . . . . . . . . . . . B-2
Replace any Aliases to Local I/O Tags. . . . . . . . . . . . . . B-4

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 Chapter 1

ControlLogix® Redundancy Overview

Introduction This chapter gives you an overview of the ControlLogix redundancy

system, including terms that are commonly used.

For information on: See page:

Basic Operation 1-1
Switchover 1-2
Synchronization 1-4
Crossloading Tag Values 1-5
ControlNet Node Addresses 1-6
Quick Start Checklists 1-7

Basic Operation The ControlLogix redundancy system uses an identical pair of

ControlLogix chassis to keep your machine or process running if a
problem occurs with a controller.

The following diagram shows the layout of a simple redundant set-up.

ControlNet™ Network 1 -
HMI communications ControlNet Network 2 -
I/O communications

identical pair of
ControlLogix chassis that at least 2 other
control your machine or ControlNet nodes
process

computer that is connected to the

network access port of a remote node
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1-2 ControlLogix® Redundancy Overview

Redundancy requires no additional programming and is transparent to

any devices connected over the ControlNet™ network. It uses
1757-SRM modules to maintain communication between the pair of
redundant chassis.

In a redundant system, the following terms describe the relationship

between the two redundant chassis:

Term: Description:
primary controller The controller that is currently controlling the machine or process.
primary chassis The chassis that contains the primary controller.
secondary controller The controller that is standing by to take control of the machine or process. A secondary
controller always resides in a different chassis than the primary controller.
secondary chassis The chassis that contains the secondary controller.
switchover Transfer of control from the primary controller to the secondary controller. After a
switchover, the controller that takes control becomes the primary controller. Its partner
controller (the controller that was previously the primary controller) becomes the
secondary controller.

Switchover When a failure occurs in any of the components of the primary

chassis, control switches to the secondary controller. A switchover
occurs for any of the following reasons:

• any of the following situations in the primary chassis:

– loss of power
– failure or major fault of the controller
– failure of a 1756-CNB/D or -CNBR/D module
– failure of a 1757-SRM module
– break or disconnection of a ControlNet tap
– removal or insertion of a module
• command from the primary controller
• command from RSLinx® software

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 ControlLogix® Redundancy Overview 1-3

IMPORTANT Use of the Network Access Port (NAP)

Do not connect any device to the network access port (NAP) of a 1756-CNB/D or
-CNBR/D module in a redundant chassis.
• If you connect a device to the NAP of a CNB module in a redundant chassis, a
switchover will fail to occur if the CNB module is disconnected from the network.
While the CNB module is disconnected from the network, the controller will be
unable to control any I/O devices through that CNB module.
• If you connect a workstation to the NAP of a CNB module in a redundant chassis, the
workstation will be unable to go online after a switchover.
To connect a device to a ControlNet network via a NAP, use a NAP that is outside of a
redundant chassis.

Depending on how you organize your RSLogix™ 5000 project,

outputs may or may not experience a change in state (bump) during a
switchover:

• During the switchover, outputs that are controlled by the highest

priority task will experience a bump-less switchover. (i.e.,
Outputs will not revert to a previous state.)
• Outputs in lower priority tasks may experience a change of
state.

The switchover time of a redundant system depends on the type of

failure and the network update time (NUT) of the ControlNet network.
For a NUT of 10 ms, the switchover time is approximately 80 ms to
220 ms.

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1-4 ControlLogix® Redundancy Overview

Synchronization To take over control, the secondary controller requires the same
project as the primary controller. It also requires up-to-date tag values.
The following terms describe the process of communication between
the two controllers.

Term: Description:
crossload The transfer of any or all of the contents of the primary controller to the secondary
controller. This could be updated tag values, force values, online edits, or any other
information about the project. A crossload occurs initially when the controllers synchronize
and then repeatedly as the primary controller executes its logic.
synchronize The process that readies a secondary controller to take over control if a failure occurs in
the primary chassis. During synchronization, the 1757-SRM modules check that the
partner modules in the redundant chassis pair are compatible with each other. The SRM
module also crossloads (transfers) the content of the primary controller to the secondary
controller.

Synchronization occurs when you turn on power to the secondary chassis. It may also
occur at other times.
disqualified Indicates that the secondary control has failed to synchronize with the primary controller. If
a secondary controller is disqualified, it is unable to take over control of the machine or
process. You also have the option of manually disqualifying a secondary controller.

The 1757-SRM modules maintain communication between the primary

and secondary chassis.

primary chassis

1757-SRM modules
crossload

secondary chassis

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 ControlLogix® Redundancy Overview 1-5

In a pair of redundant chassis, the first chassis that you turn on

becomes the primary chassis. When you turn on power to the
secondary chassis, that chassis synchronizes itself with the primary
chassis.

• You do not download the project to the secondary controller.

While the secondary controller is synchronizing with the primary
controller, the 1757-SRM modules automatically transfer the
project from the primary controller to the secondary controller.
• Once the secondary controller is synchronized, the 1757-SRM
modules keep the controller synchronized by crossloading any
changes that occur in the primary controller. These changes
include:
– online edits
– force values
– changes to properties
– changes to data
– results of logic execution
• Although online edits automatically crossload to the secondary
controller, they become inactive if a switchover occurs before
you assemble them into the project. This prevents an incorrect
online edit from faulting both the primary and secondary
controller. You have the option to keep the edits active after a
switchover (at the risk of faulting both controllers).

Crossloading Tag Values At the end of each program, the primary controller pauses its
execution to crossload the result of any output instruction that
executed in the program. This results in an increased program scan
time for a synchronized redundancy system.

scan time of program

execute program in crossload results to

primary controller secondary controller

start of program end of program

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1-6 ControlLogix® Redundancy Overview

ControlNet Node Addresses Each CNB module in a redundant chassis shares a pair of ControlNet
node numbers with its partner in the other chassis.

Each pair of CNB modules are set to

the same node number.
1 2 3 1 2 3
0 4 0 4
7 6 5 7 6 5

primary secondary
chassis chassis

24 25
CNB modules in the primary chassis CNB modules swap node numbers.
use the node number to which they
are set. switchover

1 2 3 1 2 3
0 4 0 4
7 6 5 7 6 5

secondary primary
chassis chassis

25 24
CNB modules in the secondary chassis use CNB modules swap node numbers.
the node number to which they are set plus 1.

Workstations and HMIs connect to the node Workstations and HMIs continue to connect
number of the primary chassis. to the same node number.

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 ControlLogix® Redundancy Overview 1-7

Quick Start Checklists The following checklists provide a summary of the criteria for a
successful ControlLogix redundancy system. See the remaining
chapters for more information on each parameter.

System Lay-Out
Parameter: Criteria: See page:
❑ 1. Type of network ControlNet™ networks are the primary networks for the system. OK to bridge to devices 2-2
on other networks, such as EtherNet/IP, DeviceNet™, Universal Remote I/O, and DH+™
networks.
❑ 2. Number of Separate ControlNet networks for scheduled communications (I/O, produced/consumed 2-2
ControlNet networks tags) and unscheduled communications (HMI, workstations, message instructions)
❑ 3. Network update • NUTs ≤ 90 ms 2-9
times • NUTs ≤ specified relationship to each other
❑ 4. I/O Placement • All I/O modules in remote chassis or DIN rails (no I/O in the local chassis) 2-2, 2-4
• All I/O in only the following locations:
• same ControlNet network as the redundant controllers (no bridging)
• DeviceNet™ network (via a 1756-DNB module in a remote chassis)
• universal remote I/O network (via a 1756-DHIRO module in a remote chassis)
❑ 5. Number of At least 2 nodes on each network in addition to the CNBs in the redundant chassis 2-7
ControlNet nodes (I.e., Each ControlNet network has at least 4 nodes.)
❑ 6. ControlNet node • Non-redundant nodes use the lowest node numbers 1-6, 2-7
assignments • CNB modules in the redundant chassis set close to the SMAX.
• 2 consecutive node addresses for each set of partner CNB modules (one in each
chassis)
• Switches of each partner CNB module set to the same node address
❑ 7. PanelView™ • ≤ 3 terminals per CNB module 2-2
terminals • ≤ 4 terminals per controller
❑ 8. Network Access No devices connected to the network access ports of CNB modules in the redundant 2-2
Ports chassis

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1-8 ControlLogix® Redundancy Overview

Redundant Chassis Configuration

Parameter: Criteria: See page:
❑ 1. Chassis size Same size chassis for each pair of redundant chassis. 2-9
❑ 2. Chassis lay-out • Only the following modules in each redundant chassis (no other modules): 2-9
• 1 controller
• 1 to 5 CNB modules
• 1 SRM module (requires 2 slots)
• Same slot assignments in each chassis
❑ 3. Controllers 1756-L55M13, -L55M14, -L55M16, -L55M23, or -L55M24 controller: 2-3
• Identical controllers for each redundant pair (same catalog number, series, revision,
and memory size)
• Enough memory for 2 copies of all data.
❑ 4. Connections Redundant controller requires 7 connections for redundancy. 2-6
❑ 5. CNB modules 1756-CNB/D or -CNBR/D module or modules: 2-9, 5-4
• Identical modules for each redundant pair (same catalog number, series, and revision)
• CPU usage ≤ 75%
• CNB modules have the same keeper information
❑ 6. SRM modules 1757-SRM module: 2-9
• Identical modules for each redundant pair (same catalog number, series, and revision)
• only 1 in each redundant chassis
• Uses 2 slots
• Requires 1757-SRCx cable (1, 3, 10, 50, and 100 meter lengths)

RSLogix™ 5000 Project

Parameter: Criteria: See page:
❑ 1. Number of Only one RSLogix 5000 project for the pair of redundant controllers. The project automatically 4-1
projects crossloads to the secondary controller when the secondary controller synchronizes with the
primary controller.
❑ 2. Controller • 1756-L55 ControlLogix5555 controller 4-2
properties • Redundancy enabled
❑ 3. Task structure • Only one task at the highest priority 4-6, 5-7
• If more than one task, all tasks periodic
❑ 4. I/O • Outputs that require a bumpless switchover are in the highest priority task 4-6
• Requested packet interval (RPI) less than or equal to 375 milliseconds. (Larger RPIs may
produce a bump at switchover.).
❑ 5. Task watchdog Watchdog time ≥ (2 * maximum_scan_time) + 100 ms 4-20
time where:
Maximum_scan_time is the maximum scan time for the entire task when the secondary
controller is synchronized.

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 ControlLogix® Redundancy Overview 1-9

RSLogix™ 5000 Project (Continued)

Parameter: Criteria: See page:
❑ 6. Minimizing • A few large programs 4-10
scan time • Minimal use of SINT or INT tags
• Related data in arrays and user-defined data types
• Boolean data in BOOL arrays
• Instructions execute only when required
❑ 7. Data integrity Special treatment for: 4-15
• Bit Shift Left (BSL) and Bit Shift Right (BSR) instructions
• FIFO Unload (FFU) instructions
• Logic that is scan-dependant
❑ 8. Produced and If you want a controller in another chassis to consume a tag from the redundant controller, use 4-6
consumed tags a comm format of None. In the I/O configuration of the consuming controller, select a comm
format of None for the remote CNB module (the CNB that is physically in the redundant
chassis).
❑ 9. Message For any MSG instruction from a controller in another chassis to a redundant controller, cache 4-6
(MSG) the connection.
instructions

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1-10 ControlLogix® Redundancy Overview

Notes:

Publication 1756-UM523C-EN-P - June 2003

 Chapter 2

Design the System

Use this chapter to design a redundancy system for a ControlLogix

controller

How to Use this Chapter To design your system, complete the following tasks:

Task: See page:

❑ Lay Out the System 2-2
❑ Place the I/O 2-4
❑ Add Additional Redundant Components 2-5
❑ Check Connection Requirements 2-6
❑ Assign ControlNet Addresses 2-7
❑ Select a Network Update Time 2-9
❑ Estimate the Switchover Time 2-11

1 Publication 1756-UM523C-EN-P - June 2003

2-2 Design the System

Lay Out the System Figure 2.1 ControlLogix redundancy requirements and recommendations

Use separate ControlNet networks for:

• scheduled communications (I/O, produced/consumed tags)
• unscheduled communications (HMI, workstations, message
instructions)
Set NUTs ≤ specified values

Multiple redundant chassis

pairs are OK.

Keep PanelView terminals within

these limits:

• ≤ 3 terminals per
CNB module
ControlNet network: • ≤ 4 terminals per
controller
• Set NUT ≤ 90 ms
• Set RPIs ≤ 375 ms

Remote location for all:

• I/O
• non-CNB communication
modules
To connect a computer to the
Assign the lowest node numbers C E D D M
N I/O modules N N H V
network via a NAP, use a remote
to non-redundant nodes. node.
B B B R I
I
O

other networks
at least 2 nodes in
addition to the CNBs in
the redundant chassis An additional node can be a:
• second CNB module in the same remote chassis or in a different remote chassis
• any other ControlNet device (not required to be keeper-capable)
• workstation that is running RSLinx software.

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 Design the System 2-3

Figure 2.2 ControlLogix redundancy requirements and recommendations

(Continued)

1756-CNB/D or -CNBR/D module or modules:

• 1-5 in each redundant chassis

• Keep CPU usage ≤ 75%,
1756-L55M13, -L55M14, -L55M16, -L55M23, or -L55M24
• Allocate 2 consecutive node addresses for each set of
controller:
partner CNB modules (one in each chassis).
• Only 1 in each redundant chassis • Assign each partner CNB module to the same node address.
• Requires enough memory for 2 copies of all data. • Assign the higher node addresses in your system to the
CNB modules in the redundant chassis.
• Requires 7 connections for redundancy.

1757-SRM module:
• only 1 in each redundant chassis
• uses 2 slots

L C C S
redundant 5 N N R
5 B B M no other modules
chassis a
M
x

identical modules:
• same slot number same size of chassis

• same catalog number, series, and revision

• same memory size (controller)

L C C S
5 N N R
redundant no other modules
5 B B M
chassis b M
x

1757-SRCx cable
• 1, 3, 10, 50, and 100 meter lengths

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2-4 Design the System

Place the I/O In a ControlLogix redundancy system, place all I/O in only the
following locations:

✔ same ControlNet network as the redundant controllers (no

bridging to I/O modules on another ControlNet network)
✔ DeviceNet network
✔ universal remote I/O network

redundant chassis pair

C D D C E
ControlNet network N I/O modules H N N N remote chassis
B R B B B
I
O
I/O – No

EtherNet/IP network HMI – Yes

I/O – No

ControlNet network HMI – Yes

I/O – Yes

DeviceNet network HMI – Yes

I/O – Yes

universal remote I/O network HMI – Yes

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 Design the System 2-5

Add Additional Redundant In addition to using redundant pairs of controllers, you have the
option of adding the following redundant components to your system:
Components
• Redundant ControlNet Media
• Redundant Power Supplies

Redundant ControlNet Media

Redundant ControlNet media prevents a loss of communication if a

trunkline or tap is severed or disconnected. It uses the following
components:

• 1756-CNBR ControlNet modules

• two identical ControlNet links

ControlLogix chassis with ControlNet node

1756-CNBR module

redundant media

ControlNet node

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2-6 Design the System

Redundant Power Supplies

Redundant power supplies let you maintain power to a ControlLogix

chassis if a power supply fails. Redundant power supplies use the
following hardware:

• two redundant power supplies, any combination of 1756-PA75R

and 1756-PB75R
• 1756-PSCA chassis adapter module, in place of the standard
power supply
• two 1756-CPR cables to connect the power supplies to the
1756-PSCA adapter
• user-supplied annunciator wiring to connect the power supplies
to the input modules, if needed

1756-PA75R or 1756-PA75R or
1756-PB75R 1756-PB75R

1756-CPR cable annunciator wiring

1756 digital
ControlLogix chassis with input module
1756-PSCA module

Check Connection Make sure that each controller in a redundant chassis has available
enough connections for redundancy communications. Redundancy
Requirements communications require the following number of additional
connections:

This module: Uses this many additional Description:

connections for redundancy:
controller 7 2 for the SRM

5 for the partner

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 Design the System 2-7

Assign ControlNet
Addresses

IMPORTANT 1. Make sure that your network has at least 2 nodes in addition to
the redundant chassis pair. An additional node can be a:

• second CNB module in the same remote chassis or in a

different remote chassis
• any other ControlNet device
• workstation that is running RSLinx software.

If your ControlNet network contains only one node other than

the redundant chassis pair, that node will drop its connections
during a switchover. This may cause the outputs of that node to
change state during the switchover.

IMPORTANT 2. Assign the lowest ControlNet addresses to I/O chassis and other
remotely-located chassis. (I.e., Do not assign the lowest
addresses to the redundant chassis pair.)

If you assign the lowest address to a CNB module in the

redundant chassis pair:

• On a switchover, you may temporarily lose communication

with I/O modules, produced tags, and consumed tags.
• If you remove the CNB module from the primary chassis
while chassis power is on, you may temporarily lose
communication with I/O modules, produced tags, and
consumed tags.
• If every ControlNet node powers down at the same time (e.g.,
a plant-wide power loss), you may have to cycle the power to
the primary chassis to restore communication.

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2-8 Design the System

3. Allocate two consecutive ControlNet addresses for each pair of

redundant chassis (e.g., nodes 3 and 4).
• If each redundant chassis has multiple CNB modules, assign a
pair of node numbers for each pair of CNB modules (one in
each chassis).
• Do not configure any other device on the ControlNet network
for either of these addresses. For example, if you allocated
nodes 3 and 4 for the redundant chassis, then no other device
should use those node numbers.

Use the following worksheet to record the slot number and

node numbers for each pair of CNB modules:

Table 2.1 Slot and node numbers for 1756-CNB/D or -CNBR/D modules

Pair of CNB modules (one in each Slot and node numbers

redundant chassis)
Slot # Primary node # Secondary node #
(primary node # + 1)
1st pair of CNB modules

2nd pair of CNB modules

3rd pair of CNB modules

4th pair of CNB modules

5th pair of CNB modules

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 Design the System 2-9

Select a Network Update Use a network update time (NUT) that is less than or equal to the
following values.
Time
If you have: And: Then:
only one CNB module in a redundant Use a NUT that is less than or equal to
chassis 90 milliseconds.
more than one CNB module in a redundant the CNB modules are on the same network Use a NUT that is less than or equal to
chassis 90 milliseconds.
the CNB modules are on different networks The NUT of each network must be within
the values indicated in Table 2.2.

If you use a larger NUT, the controller could lose its connection with a
module during a switchover. This could cause outputs to change state.

Table 2.2 NUTs for multiple ControlNet networks Table 2.2 NUTs for multiple ControlNet networks (Continued)

If the smallest Then the largest NUT on any other If the smallest Then the largest NUT on any other
NUT on a network network must be less than or equal NUT on a network network must be less than or equal
is (ms): to (ms): is (ms): to (ms):
2 15 20 52
3 17 21 55
4 19 22 57
5 21 23 59
6 23 24 62
7 25 25 64
8 27 26 66
9 29 27 68
10 31 28 71
11 33 29 73
12 35 30 75
13 37 31 78
14 39 32 80
15 41 33 82
16 43 34 84
17 46 35 87
18 48 36 89
19 50 37 - 90 90

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2-10 Design the System

EXAMPLE Network Update Times for Multiple ControlNet Networks

If the NUT of this network is 5 ms…

Then the NUT of this network must be 21 ms or less.

L C S C
5 N R N
5 B M B
M
x

Network 1 Network 2

L C S C
5 N R N
5 B M B
M
x

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 Design the System 2-11

Estimate the Switchover The switchover time of a redundant system depends on the network
update time (NUT) of the ControlNet network. To estimate the
Time switchover time, use the following formulas:

For this type of failure: If the NUT is: The switchover time is: Example:
loss of power ≤6 60 ms For a NUT of 4 ms, the switchover time
– or – is approximately 60 ms.
module failure
≥7 5 (NUT ) + MAX (2 (NUT ), 30) For a NUT of 10 ms, the switchover
time is approximately 80 ms.
CNB module cannot communicate 14 (NUT ) + MAX (2 (NUT ), 30) + 50 For a NUT of 10 ms, the switchover
with any other node time is approximately 220 ms.

where:

NUT is the network update time of the network.

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2-12 Design the System

Notes:

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 Chapter 3

Install the System

When to Use this Chapter Use this chapter to install the hardware of your ControlLogix
redundancy system.

How to Use this Chapter To install your system, complete the following tasks:

Task: See page:

❑ Review the Preliminary Information 3-1
❑ Install the Chassis for the Controllers 3-4
❑ Install Modules in the First Redundant Chassis 3-4
❑ Install Modules in the Second Redundant Chassis 3-4
❑ Install the Remote Chassis or Rails 3-4
❑ Flash the Modules 3-4
❑ Synchronize the Controllers 3-10
❑ Download the Project to the Primary Controller 3-12
❑ Schedule the Networks 3-13
❑ Test the Switchover 3-17

Preliminary Information

IMPORTANT Use of the Network Access Port (NAP)

Do not connect any device to the network access port (NAP) of a 1756-CNB/D or
-CNBR/D module in a redundant chassis.
• If you connect a device to the NAP of a CNB module in a redundant chassis, a
switchover will fail to occur if the CNB module is disconnected from the network.
While the CNB module is disconnected from the network, the controller will be
unable to control any I/O devices through that CNB module.
• If you connect a workstation to the NAP of a CNB module in a redundant chassis, the
workstation will be unable to go online after a switchover.
To connect a device to a ControlNet network via a NAP, use a NAP that is outside of a
redundant chassis.

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This chapter provides the sequence of tasks and the critical actions for
the successful installation of your ControlLogix redundancy system. It
does not replace the installation instructions for the components of the
system. As you install your system, refer to the following publications:

Install this component: According to this publication:

1756-A4, -A7, -A10, -A13, or -A17 chassis ControlLogix Chassis Installation Instructions, publication 1756-IN080
1756-PA72 or -PB72 power supply ControlLogix Power Supplies Installation Instructions, publication 1756-5.67
1756-PA75 or -PB75 power supply ControlLogix Power Supplies Installation Instructions, publication 1756-5.78
1756-L55M13, -L55M14, or -L55M16 controller ControlLogix Controller and Memory Board Installation Instructions, publication
1756-IN101
1756-CNB/D or -CNBR/D module ControlLogix ControlNet Bridge Installation Instructions, publication 1756-IN571
1757-SRM module ProcessLogix/ControlLogix System Redundancy Module Installation Instructions,
publication 1757-IN092

Installation instructions provide important information, such as

detailed installation steps, safety considerations, enclosure
requirements, and hazardous location information.

Before you install the system, review the following guidelines for safe
handling of ControlLogix components:

WARNING When you insert or remove a module while backplane power is on,
an electrical arc can occur. This could cause an explosion in
hazardous location installations. Be sure that power is removed or the

! area is nonhazardous before proceeding.

Repeated electrical arcing causes excessive wear to contacts on both a

module and its mating connector. Worn contacts may create electrical
resistance that can affect module operation.

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 Install the System 3-3

ATTENTION Preventing Electrostatic Discharge

This equipment is sensitive to electrostatic discharge, which can cause

! internal damage and affect normal operation. Follow these guidelines

when you handle this equipment:
•
•
Touch a grounded object to discharge potential static.
Wear an approved grounding wriststrap.
• Do not touch connectors or pins on component boards.
• Do not touch circuit components inside the equipment.
• If available, use a static-safe workstation.
• When not in use, store the equipment in appropriate static-safe
packaging.

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3-4 Install the System

Install the Chassis for the

Controllers
1.

42798

2.

1. Install the two ControlLogix chassis that will contain the

controllers (i.e., the redundant chassis):

• Place the chassis within the length of your 1757-SRCx cable.

• Install each chassis according to the ControlLogix Chassis
Installation Instructions, publication 1756-IN080.
• If you are converting an existing system that contains local
I/O modules, you still need two additional chassis. A
redundant system can use only remote I/O.

2. For each chassis, install a ControlLogix power supply according

to the corresponding installation instructions:

Install this power supply: According to this publication:

1756-PA72 ControlLogix Power Supplies Installation
Instructions, publication 1756-5.67
1756-PB72
1756-PA75 ControlLogix Power Supplies Installation
Instructions, publication 1756-5.78
1756-PB75

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 Install the System 3-5

Install Modules in the First

Redundant Chassis
IMPORTANT Set the rotary switches of the 1756-CNB/D or
-CNBR/D modules for both redundant chassis to the
same node address.

1. Set the rotary switches of each of the 1756-CNB/D or -CNBR/D

modules to the primary node number from Table 2.1 on
page 2-8.
42796

For example, if you allocated nodes 3 and 4 for the redundant

chassis, set both CNB modules to node 3.

2. This is only an example. You can install the

module in any slot.

C
N
B

3.

42799

2. Install a 1756-CNB/D or -CNBR/D module. See ControlLogix

ControlNet Bridge Installation Instructions, publication
1756-IN571.

WARNING If you connect or disconnect the ControlNet cable

with power applied to this module or any device on
the network, an electrical arc can occur. This could

! cause an explosion in hazardous location

installations.
Be sure that power is removed or the area is
nonhazardous before proceeding.

3. Connect the CNB module to the ControlNet network.

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3-6 Install the System

4. 5. This is only an example. You can install the

modules in any slot.

L C S
5 N R
5 B M

42799

4. Install the 1756-L55Mxx controller. See ControlLogix Controller

and Memory Board Installation Instructions, publication
1756-IN101.

5. Install the 1757-SRM module. See ProcessLogix/ControlLogix

System Redundancy Module Installation Instructions,
publication 1757-IN092.

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 Install the System 3-7

Install Modules in the

Second Redundant Chassis
1.

L C S L C S
5 N R 5 N R
5 B M 5 B M

2.

42800
3.

IMPORTANT • The modules in each redundant chassis must

match each other slot-by-slot.
• Set the rotary switches of the 1756-CNB/D or
-CNBR/D modules for both redundant chassis to
the same node address.

1. For each module in the first redundant chassis, install an

identical module into the same slot of the second redundant
chassis.

2. Connect the CNB module (s) to the ControlNet network.

3. Connect the 1757-SRC1, -SRC3, -SRC10, -SRC50, or -SRC100 fiber

optic cable to the 1757-SRM modules.

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3-8 Install the System

Install the Remote Chassis You must install all I/O modules and additional types of
communication modules in remote chassis or on DIN rails. The
or Rails following example shows a remote 1756 chassis. You can use any
type of chassis or device that you can connect to the ControlNet
network.

EtherNet/IP network

L C S L C S C E
5 N R 5 N R N I/O modules N
5 B M 5 B M B B

42197

other ControlNet node (s)

You must have at least 2 other nodes in addition to the

redundant chassis pair. See “Lay Out the System” on
page 2-2.

IMPORTANT If you connect the workstation to the network via a network access port on a CNB
module, use a CNB module in a remote chassis. This lets a switchover occur after the
failure of a ControlNet tap of a primary chassis.

As you install the chassis, follow these guidelines:

• Do not assign any device to the address of the CNB modules in

the redundant chassis plus one.

For example, if you set the rotary switches of the CNB modules
in the redundant chassis to node 11, no other device should use
node 12.

• Use a remote chassis for communication modules such as:

– 1756-ENET or -ENB
– 1756-DHRIO
– 1756-MVI
– 1756-DNB

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 Install the System 3-9

Flash the Modules 1. Turn on the power to one of the redundant chassis.

Redundancy Module
2. Wait for the 1757-SRM module to display PRIM.

PRIM 3. Flash upgrade each module in the chassis with a compatible

revision of firmware.
PRI COM OK
• See the ControlFLASH Firmware Upgrade Kit User Manual,
publication 1756-6.5.6.
42801
• To find the chassis in RSLinx software, use the node number
that the CNB module in the chassis displays.

4. Turn off the power to the chassis.

5. Turn on the power to the second redundant chassis.

6. Wait for the 1757-SRM module to display PRIM.

7. Flash upgrade each module in the chassis with a compatible

revision of firmware. Use the same revisions that you used for
the first redundant chassis.

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Synchronize the Controllers To synchronize the controllers in the redundant chassis pair:

❑ Set the Auto-Synchronization Option to Always

❑ Synchronize the Controllers

Set the Auto-Synchronization Option to Always

1. Open RSLinx software.

2. From the Communications menu, choose RSWho.

To expand a network one level, do one of − Workstation

the following:
+ Linx Gateways, Ethernet
• Double-click the network.
+ AB_KTC-x, ControlNet
• Select the network and press
the → key.
• Click the + sign.

3. Navigate to the CNB module of the primary chassis. The primary

chassis uses the node to which its rotary switches are set.

− Workstation
+ Linx Gateways, Ethernet
− AB_KTC-x, ControlNet
primary chassis + n, 1756-CNB/D

4. Expand the CNB module of the primary chassis.

5. Expand the backplane.

− Workstation
+ Linx Gateways, Ethernet
− AB_KTC-x, ControlNet
− n, 1756-CNB/D
− Backplane, 1756-Ax
xx, 1756 module, 1757-SRM

6. Right-click the 1757-SRM module and choose

Module Configuration.

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 Install the System 3-11

7. Set the Auto-Synchronization option = Always.

a. Click the Configuration tab.

b. Choose Always.

8. Choose OK.

Synchronize the Controllers

1. Turn on the chassis power to the partner (secondary) chassis.

2. Wait for the 1757-SRM module to complete its power-up cycle.

• The SRM module may take 1 to 3 minutes to power-up.
• It may also take several minutes to synchronize the secondary
controller.

3. In the primary chassis, what do the CNB modules display?

Primary
If: Then: Which means:
PwQS Primary with The redundant chassis are synchronized.
Synchronized
(Qualified) Go to “Download the Project to the Primary Controller“
Secondary on page 3-12.
PwDS Primary with A problem exits. The redundant chassis are not
Disqualified synchronized.
Secondary
Go to “Troubleshoot a Failure to Synchronize” on
page 5-3.

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3-12 Install the System

Download the Project to the You only have to download the project to the primary controller.
When the secondary controller is synchronized, the system
Primary Controller automatically crossloads the project to the secondary controller.

IMPORTANT If the secondary chassis becomes disqualified after

you download the project, make sure:
• the project is configured for a 1756-L55
ControlLogix5555 controller
• redundancy is enabled
See “Configure the Project for the Controllers” on
page 4-2.

1. Open or create the RSLogix 5000™ project for the controller.

2. From the File menu, choose Save.

3. From the Communications menu, choose Who Active.

To expand a network one level, do one of − Workstation

the following:
+ Linx Gateways, Ethernet
• Double-click the network.
+ AB_KTC-x, ControlNet
• Select the network and press
the → key.
• Click the + sign.

4. Navigate to the CNB module of the primary chassis. The primary

chassis uses the node to which its rotary switches are set.

− Workstation
+ Linx Gateways, Ethernet
− AB_KTC-x, ControlNet
primary chassis + n, 1756-CNB/D
secondary chassis + n + 1, 1756-CNB/D

5. Expand the CNB module of the primary chassis.

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6. Expand the backplane.

− Workstation
+ Linx Gateways, Ethernet
− AB_KTC-x, ControlNet
− n, 1756-CNB/D
− Backplane, 1756-Ax
+ xx, 1756-L55Mxx

7. Select the controller and choose Download.

A confirmation box opens.

8. Choose Download.

Schedule the Networks

IMPORTANT Before you schedule a ControlNet network, turn on

the power to both redundant chassis. If you schedule
a ControlNet network while the secondary chassis is
off, the keeper signature of a CNB module may not
match its partner, and the secondary chassis will fail
to synchronize.

Use the following procedures to schedule your network:

❑ Schedule a New Network

❑ Update the Schedule of an Existing Network
❑ Check the Keepers
❑ Save the Project for Each Controller

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.

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3-14 Install the System

5. Select your ControlNet network and choose OK.

6. Select the Edits Enabled check box.

7. From the Network menu, choose Properties.

8. From the Network Parameters tab, type or select the following

parameters:

In this box: Specify:

Network Update Time repetitive time interval in which data is sent over the ControlNet network
Max Scheduled Address greatest node number to use scheduled communications on the network
Max Unscheduled Address greatest node number that you will use on the network
Media Redundancy channels in use
Network Name name for the network

9. choose 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 choose Save.

13. Select the Optimize and re-write Schedule for all Connections
button (default) and choose OK.

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Update the Schedule of an Existing 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 choose Open.

5. From the Network menu, choose Online.

6. Select the Edits Enabled check box.

7. From the Network menu, choose Properties.

8. From the Network Parameters tab, update the following

parameters:

In this box: Specify:

Max Scheduled Address greatest node number to use scheduled communications on the network
Max Unscheduled Address greatest node number that you will use on the network

9. choose OK.

10. From the Network menu, choose Single Pass Browse.

11. From the File menu, choose Save.

12. Select the Optimize and re-write Schedule for all Connections
button (default) and choose OK.

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Check the Keepers

On a ControlNet network, each keeper must:

• be able to take over the keeper duties if the current keeper

drops off the network
• use the same configuration (signature) regardless of which
keeper comes online first after a major network disturbance
(cable short, system power cycle, etc.)

After you schedule your ControlNet networks:

1. 2.

Keeper Capable Node Active Keeper Valid Keeper

offline file N/A N/A
01 NO YES
02 YES YES

1. Make sure the network shows all keeper capable nodes.

2. Make sure that each node is a valid keeper.

For more information, see “Update a Keeper Signature” on page 5-4.

Save the Project for Each Controller

After your schedule your ControlNet networks, save the online project
of each controller. This lets you download a project in the future
without having to reschedule the networks.

For each controller (redundant and non-redundant) on a ControlNet

network:

1. Go online to the controller.

2. Save the project.

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 Install the System 3-17

Test the Switchover To test a switchover, use RSLinx software to manually initiate a
switchover. During a switchover, the CNB modules in the new
primary chassis display a sequence of status messages. Typically, the
modules displays the following sequence:

PwNS ⇒ PwDS ⇒ PwQg ⇒ PwQS

primary with primary with primary with primary with
no secondary disqualified synchronizing synchronized
secondary (qualifying) (qualified)
secondary secondary

43130

Make Sure the Auto-Synchronization Option = Always

1. Display RSLinx software.

2. From the Communications menu, choose RSWho.

3. Expand the network until you see the 1757-SRM module in the
primary chassis.

− Workstation
+ Linx Gateways, Ethernet
− AB_KTC-x, ControlNet
− n, 1756-CNB/D
− Backplane, 1756-Ax
xx, 1757-SRM

4. Right-click the 1757-SRM module and choose

Module Configuration.

5. Set the Auto-Synchronization option = Always.

a. Click the Configuration tab.

b. Choose Always.

6. Choose Apply.

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3-18 Install the System

Initiate a Switchover

1. Click the Synchronization tab.

2. Choose Initiate Switchover and then choose Yes to confirm.

Make Sure the Controllers are Synchronized

If you set the Auto-Synchronization option to Always, the SRM

modules try to synchronize the controllers after a switchover.

1. To monitor the synchronization progress, click the

Synchronization Status tab.

If the controller contains a large project, the system may spend

some time synchronizing the secondary controller.

2. If the Secondary Readiness remains Disqualified, see

“Troubleshoot a Failure to Synchronize” on page 5-3.

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 Chapter 4

Configure and Program the Controller

When to Use this Chapter After you have installed your system, use this chapter to configure and
program the controller for redundancy.

IMPORTANT Create and maintain only one RSLogix 5000 project

for the pair of redundant controllers. When you
download the project to the primary controller, the
project automatically crossloads to the secondary
controller.

How to Use this Chapter To configure and program your controller, complete the following
tasks:

Task: See page:

❑ Configure the Project for the Controllers 4-2
❑ Configure Communications 4-6
❑ Estimate the Scan Time of a Program 4-9
❑ Minimize Scan Time 4-10
❑ Maintain the Integrity of Your Data During a Switchover 4-15
❑ Set the Task Watchdog Times 4-20

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4-2 Configure and Program the Controller

Configure the Project for To configure the project for your controller:
the Controllers ❑ Determine When to Retain Test Edits
❑ Determine How to Reserve Memory
❑ Configure a Controller for Redundancy

Determine When to Retain Test Edits

When you edit your logic while online with the controller, it is
possible for those edits to fault the controller and cause a switchover.

Test Edits

If the test edits fault the primary controller, it is likely they will fault
the secondary controller as well. To prevent this from occurring, any
test edits are deactivated (untested) during a switchover. As an option,
you can keep the edits active after a switchover:

If you want to: Then:

prevent an incorrect online edit from Do not retain test edits (default setting).
faulting both the primary and secondary
controller
keep test edits active during a switchover Retain test edits.
(at the risk of faulting both controllers)

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 Configure and Program the Controller 4-3

Determine How to Reserve Memory

When the secondary controller receives crossload data, it first buffers

tag data in a quarantine section of memory. When it has all of the data
and knows it is valid, it moves the data into the main memory area.
That is why a redundant controller requires twice as much memory
for tags as a non-redundant controller.

The controller sets up the quarantine area at the time of download:

• The controller divides its memory into two sections:

– tags, including a quarantine area
– logic
• The controller also divides its unused memory. It reserves a
specific amount for tags and the rest for logic.

You configure how to reserve unused memory between tags and

logic. You do this offline only, before you download the project.

If you plan to: Then:

while online, create roughly the same amount of new tags Leave the default setting.
and new logic
while online, create a relatively large amount of new tags Drag to slider toward Tags.
but a much smaller amount of new logic
while online, create a relatively large amount of new logic Drag to slider toward Logic.
but a much smaller amount of new tags

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4-4 Configure and Program the Controller

Configure a Controller for Redundancy

1. Open or create the RSLogix 5000™ project.

2. On the Online toolbar, click the controller button.

3. Does the General tab show that the controller type is a 1756-L55
controller?

If: Then:
No A. Click the Change Type button.

B. Select a 1756-L55 controller.

C. Choose OK.
Yes Go to step 4.

4. Click the Redundancy tab.

5. Select the Redundancy Enabled check box.

6. Click the Advanced button.

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 Configure and Program the Controller 4-5

7. We recommend that you leave this check box cleared

(unchecked). This prevents an incorrect online edit from faulting
both the primary and secondary controller.

If you want any test edits to remain active during a switchover

(at the risk of faulting both controllers), then check this check
box.

8. For online editing, choose how you want to reserve any free
memory.

9. Choose

10. To close the Controller Properties dialog box,

choose

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4-6 Configure and Program the Controller

Configure Communications A redundant system requires some specific configuration choices for
successful communications. Use this section for guidance on how to
configure the following elements for redundancy:

❑ Configure I/O
❑ Configure Produced Tags
❑ Configure Message (MSG) Instructions
❑ Configure Tags for an HMI

Configure I/O

IMPORTANT For each module in your system, make sure that the
requested packet interval (RPI) is less than or equal
to 375 milliseconds. If you use a larger RPI, the
controller could lose its connection with the module
during a switchover. This could cause outputs to
change state.

For any outputs that require a bumpless switchover:

• Put those outputs in the highest priority task.

• Configure only that task at the highest priority.

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 Configure and Program the Controller 4-7

Configure Produced Tags

IMPORTANT During a switchover, the connection for tags that are

consumed from a redundant controller may time out.
• The data does not update.
• The logic acts on the last data that it received.
After the switchover, the connection reestablishes
and the data begins to update again.

If you want a controller in another chassis to consume a tag from the

redundant controller, use a comm format of None. In the I/O
configuration of the consuming controller, select a comm format of
None for the remote CNB module (the CNB that is physically in the
redundant chassis).

produced tag
To the controller with the consumed tag, this
is the remote CNB module.
redundant
chassis

L C S
5 N R
5 B M
M
x

data

consumed tag
remote chassis

C L
N 5
B 5
M
x

In the I/O configuration of this controller, select a comm format of

None for the remote CNB module.

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4-8 Configure and Program the Controller

Configure Message (MSG) Instructions

If the MSG instruction Then:

is:
from a redundant In a redundant controller, any MSG instruction that is in progress during a switchover experiences an error.
controller (The ER bit of the instruction turns on.) After the switchover, normal communication resumes.
to a redundant controller For any MSG instruction from a controller in another chassis to a redundant controller, cache the connection:

Properties of the Message to the Redundant Controller

path to the
redundant controller

42977

Leave this box checked

Configure Tags for an HMI

If you plan to monitor tags directly in the secondary controller (not

typical), monitor from no more than 3 devices through a CNB module.

You can monitor tags in a secondary controller only via:

• RSLogix 5000 software

• Any method that does not try to create OPC optimized packets.
Only a primary controller can create an OPC optimized packet.

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 Configure and Program the Controller 4-9

Estimate the Scan Time of a At the end of each program, the primary controller crossloads fresh
data to the secondary controller, as described in Chapter 1. This keeps
Program the secondary up-to-date and ready to take over control but also
increases the scan time when compared to a non-redundant system.

scan time of program

execute program in crossload results to

primary controller secondary controller

start of program end of program

The length of time for the crossload depends on the amount of data
that has to be crossloaded. Crossloading also requires a small amount
of overhead time to tell the secondary controller which program the
primary controller is executing.

The primary controller crossloads any tag to which an instruction

wrote a value (even the same value) since the last crossload. To
estimate the time for the crossload, use the following formula:

Crossload time = (0.002 to 0.003 ms * DINTs) + 0.3 to 0.5 ms of

overhead

where:

DINTs is the amount of tag data to be crossloaded, measured in

4-byte words.

In addition, a task time that is less than the crossload time could flood
the SRM module with data. When this occurs, the SRM module pauses
for approximately 5 ms to clear the overflow buffer. This adds 5 ms to
the scan time.

To determine the amount of crossload data, use a GSV instruction to

access the REDUNDANCY object (only available for a controller that is
configured for redundancy). For more information, see “Get System
Values” on page 5-20.

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4-10 Configure and Program the Controller

Minimize Scan Time To minimize the scan time of your project, follow these guidelines:

❑ Use a Few Large Programs

❑ Minimize the Use of SINT or INT tags
❑ Use Arrays and User-Defined Data Types
❑ Pack Data into Arrays
❑ Execute Instructions Only When Required

Use a Few Large Programs

Since the primary controller pauses its execution at the end of every
program to crossload data, combine your logic into a few relatively
large programs instead of many smaller programs.

• A fewer number of programs requires fewer crossloads.

• Larger programs pack more data into each crossload since more
logic will have executed before the crossload.

Divide each program into whatever number of routines makes the

most sense for your logic. The number of routines have no effect on
the frequency of crossloads.

Minimize the Use of SINT or INT tags

Regardless of whether or not it is configured for redundancy, a

ControlLogix controller typically compares or manipulates values as
32-bit values (DINTs or REALs).

• The controller typically converts a SINT or INT value to a DINT

or REAL value before it uses the value.
• If the destination is a SINT or INT tag, the controller typically
converts the value back to a SINT or INT value.
• The conversion to or from SINTs or INTs occurs automatically
with no extra programming. But it takes extra execution time
and memory.

To increase the efficiency of your logic, minimize the use of SINT or

INT data types.

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 Configure and Program the Controller 4-11

Use Arrays and User-Defined Data Types

To update the secondary controller, the primary controller divides its

memory into blocks of 256 bytes. Anytime an instruction writes a
value, the primary controller crossloads the entire block that
contained the value. For example, if your logic writes only 1 BOOL
value to a block, the controller crossloads the entire block (256 bytes).

To minimize scan time, organize your data into arrays and

user-defined data types (structures) whenever possible. Arrays and
structures provide these advantages:

• Data is more compact. This lets the primary controller crossload

it more quickly.
• Related data is grouped together.
– Related data is likely to change at the same time.
– Since the controller crossloads data in 256 byte blocks, fewer
blocks may be required than if the same amount of data was
spread across many individual tags.

To create arrays and user-defined data types, see the Logix5000

Controllers Common Procedures, publication 1756-PM001.

Pack Data into Arrays

The minimum memory allocation for a tag is 4 bytes. When you create
a tag that stores data that requires less than 4 bytes, the controller
allocates 4 bytes, but the data only fills the part it needs.

Data type Bits

31 16 15 8 7 1 0
Bool not used 0 or 1
Sint not used -128 to +127
Int not used -32,768 to +32767
Dint -2,147,483,648 to +2,147,483,647
Real -3.40282347E to -1.17549435E-38 (negative values)
38
0
-38 38
1.17549435E to 3.40282347E (positive values)

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4-12 Configure and Program the Controller

User-defined data types and arrays pack smaller data types into 32-bit
words. For example:

• If you create 32 individual BOOL tags, the controller allocates

128 bytes for the data (32 BOOL tags x 4 bytes/tag = 128 bytes).
• If you create an array of 32 BOOLs, the controller packs them
into a 4-byte chunk of memory.

Bits
31 0
Bool_Array[31]… Bool_Array[0]

Arrays provide the greatest advantage with BOOL tags. If you have
individual SINT, INT, DINT, or REAL tags, also use arrays to pack
those tags as efficiently as possible.

One simple way to pack existing data into arrays is to convert the tags
to alias tags for elements of an array, as shown below:

BOOLs as individual tags

Same BOOLs but packed into an array

1.

2.

3.

1. Create a BOOL array.

2. Convert your BOOL tags to aliases for elements within the

BOOL array.

3. In your logic, continue to reference the existing tag names.

The system crossloads the Base tag, which in this example is the array
of BOOLs. The array is more compact than the individual tags.

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 Configure and Program the Controller 4-13

Execute Instructions Only When Required

Anytime an instruction writes a value to a tag, even if it is the same

value, the primary controller crossloads the value to the secondary
controller:

• Many instructions write a value to a tag whenever they execute.

For example, instructions such as OTL, OTU, and many
instructions with Destination operands write a value each time
the rung-condition-in is true.
• Whenever an instruction writes a value, the controller marks the
value for the next crossload. This occurs even if the instruction
wrote the same value that was previously in the tag.

To minimize scan time, execute instructions only when required, if

possible. Use techniques such as:

• Make a rung false when you don’t need to execute its

instructions.
• Divide your logic into subroutines and execute each subroutine
only when required.

This reduces the amount of crossload data, which reduces scan time.

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4-14 Configure and Program the Controller

EXAMPLE Execute an instruction only when required

Each time the following rung executes, the ADD instruction writes the sum of Tag_1 +
Tag_2 to Dest_Tag.

Regardless of whether the value in Dest_Tag changed from the last scan, the controller
marks Dest_Tag to be included in the next crossload. If your application needs to
recalculate Dest_Tag only when it gets new data, you could modify the rung as follows:

The ADD instruction now executes only when the controller gets new data
(New_Data = on). And Dest_Tag crossloads only when the ADD instruction produces a
new value.

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 Configure and Program the Controller 4-15

Maintain the Integrity of The redundancy system guarantees a bumpless switchover for any
logic in the highest priority task. In some cases, logic in lower priority
Your Data During a tasks may experience an upset when a switchover occurs. This has to
Switchover do with how data crossloads from the primary controller to the
secondary controller.

As the primary controller executes its logic, it updates the secondary

controller at the end of every program.

interruption by the program end of the program in a

in a higher priority task higher priority task

start of the program in the lower end of the program in the lower
priority task (e.g., the continuous task) priority task
A.
primary controller
C.

B.

A. The following data is sent to the secondary controller:

• data from the program in the higher priority task
• data from the first part of the program in the lower priority
task

B. Execution returns to the program in the lower priority task.

C. Data from the second part of the program in the lower priority
task is sent to the secondary controller.

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4-16 Configure and Program the Controller

When a switchover interrupts the execution of the primary controller,

the secondary controller re-executes an interrupted program from the
beginning of the program.

interruption by the program end of the program in a

in a higher priority task higher priority task

start of the program in the lower

priority task (e.g., the continuous task)
A.
• This portion of the task is not executed
primary controller
during this scan.
• If an instruction was executing at the time
of the switchover, it does not complete in
switchover B. this scan.
occurs
secondary controller

C.

A. The following data is sent to the secondary controller:

• data from the program in the higher priority task
• data from the first part of the program in the lower priority
task

B. Execution returns to the program in the lower priority task.

C. The secondary controller:

• starts the scan at the beginning of the program that was in
progress in the primary controller at the time of the
switchover
• uses the data from the last update

In this example, the secondary controller starts the scan with an

image of the data as it was during the last scan of the primary
controller.

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 Configure and Program the Controller 4-17

To find places in your logic that might be susceptible to an upset

during a switchover:

❑ Look for Array Shift Instructions

❑ Look for Logic That is Scan-Dependant
❑ Take Preventative Actions

Look for Array Shift Instructions

The following instructions might corrupt your data during a

switchover:

• BSL
• BSR
• FFU

Because these instructions shift data within an array, an interruption

by a higher priority task and a subsequent switchover leaves the data
with an incomplete shift:

• If a higher priority task interrupts one of these instructions, the

partially-shifted array values are sent to the secondary controller.
• If a switchover occurs before the instruction completes its
execution, data remains only partially shifted.
• The secondary controller starts its execution at the beginning of
the program, When it reaches the instruction, it shifts the data
again.

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4-18 Configure and Program the Controller

Look for Logic That is Scan-Dependant

A rung that must read the output of another rung during the same
scan might miss a scan during a switchover. For example:

A.

C.

D.

B.

43065

A. The CTU instruction counts each scan.

B. The EQU instruction uses the count of each scan

(scan_count.ACC ).

C. If a higher priority task interrupts the logic, the value of

scan_count.ACC is sent to the secondary controller at the end of
the program in the higher priority task.

D. If a switchover occurs before the EQU instruction, the secondary

controller starts its execution at the beginning of the program.
The EQU instruction misses the last value of scan_count.ACC.

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 Configure and Program the Controller 4-19

Take Preventative Actions

If you find a place in your logic that might be susceptible to an upset

during a switchover, take one of the following preventative actions:

1. Place Susceptible Logic in the Highest Priority Task

2. If the logic must remain in a lower priority task, take one of the
following actions:
• Use UID and UIE Instruction Pairs
• Buffer Critical Data

Place Susceptible Logic in the Highest Priority Task

• This prevents the controller from sending any data to the

secondary controller until the program finishes.
• If a switchover occurs during the program, the secondary
controller repeats the scan using the same starting data.

Use UID and UIE Instruction Pairs

Bound critical rungs with UID and UIE instruction pairs. This prevents
the higher priority task form interrupting the scan-dependent logic, as
shown below:

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4-20 Configure and Program the Controller

Buffer Critical Data

The following example shows the use of a buffer together with a BSL
instruction.

1. 2. 3.

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1. The COP instruction moves the data into a buffer array.

2. The BSL instruction uses the data in the buffer. If a switchover
occurs, the source data (array tag) remains unaffected.
3. The CPS instruction updates array tag. Since higher priority
tasks cannot interrupt a CPS instruction, the instruction keeps
the integrity of the data.

Set the Task Watchdog A redundant controller requires longer watchdog times than a
non-redundant controller. To avoid a major fault (type 6, code 1) due
Times to a watchdog time-out after a switchover, complete the following
actions:

❑ Estimate a Watchdog Time

❑ Set the Watchdog Time for a Task
❑ Determine the Scan Time of a Task

Estimate a Watchdog Time

A redundant controller requires longer watchdog times than a

non-redundant controller:

• After a switchover, the secondary controller starts the scan at the

beginning of the program that was in progress in the primary
controller at the time of the switchover.
• The watchdog timer for the task that contains the program,
however, is not reset.
• If the watchdog time does not include time for a complete
rescan of the program, a major fault could occur.

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 Configure and Program the Controller 4-21

To estimate watchdog time for a task, use the following formula:

Watchdog time ≥ (2 * maximum_scan_time) + 100 ms

where:

Maximum_scan_time is the maximum scan time for the entire task

when the secondary controller is synchronized.

Once you enter a watchdog time, use the actual scan time for a task to
revise the watchdog time, if required.

Set the Watchdog Time for a Task

To set the watchdog time for a task:

+ Controller Primary
− Tasks
+ MainTask 1. Right-click the task and choose
Properties.

2. Click the Configuration tab.

3. Type the watchdog time.

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4. Choose

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4-22 Configure and Program the Controller

Determine the Scan Time of a Task

To get the actual scan times for a task:

+ Controller Primary
− Tasks
+ MainTask 1.

1. Right-click the task and choose Properties.

2. Click the Configuration tab.

maximum time that it took to execute this task, in

microseconds

43080

3. To close the dialog box, choose

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 Chapter 5

Maintain and Troubleshoot the System

When to Use this Chapter This chapter provides a variety of procedures to assist as you
commission and operate your redundancy system.

How to Use this Chapter

If you want to: Then see this section: Which starts on page:
diagnose the cause of an unplanned switchover Determine the Cause of a Switchover 5-2
determine why the secondary controller fails to synchronize Troubleshoot a Failure to Synchronize 5-3
initiate the synchronization process Manually Synchronize the Controllers 5-6
• determine why it takes a very long time to Optimize Communication 5-7
synchronize the secondary controller
• determine why communication with your HMIs is very
slow
• determine the CPU usage of a CNB module Adjust CNB Usage 5-11
• reduce the CPU usage of a CNB module
export specific events from the SRM event log and view them Export the SRM Event Log to Microsoft® 5-15
in a Microsoft® Excel spreadsheet: Excel
change when the 1757-SRM modules try to synchronize the Configure the Auto-Synchronization 5-18
controllers Option
use ladder logic to get system or status information about Get System Values 5-20
your redundancy system
use ladder logic to initiate a redundancy action, such as Send a Message to an SRM Module 5-24
synchronize the secondary controller
• store a project to the nonvolatile memory of a Store or Load a Project Using Nonvolatile 5-30
controller in a redundant system Memory
• load a project into the controller from the nonvolatile
memory of the controller
change the revision of a module while minimizing the time Update a Module 5-31
your system is off

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5-2 Maintain and Troubleshoot the System

Determine the Cause of a If an unplanned switchover occurs, use the following tables to
determine the cause of the switchover.
Switchover
In the primary chassis, what does the CNB module display?

Front Panel: If: Then:

PwNS Go to Table 5.1
PwDS Go to Table 5.2
Look here.

43130

Table 5.1 If a CNB module displays PwNS, use this table to troubleshoot the secondary chassis.

If the secondary chassis: And each primary CNB And a secondary CNB Then:
module: module has a:
has power has a partner module in the Red OK LED Replace the CNB module.
secondary chassis
Green OK LED Check the 1756-SRC cable for a
proper connection.
does not have a partner module Install a CNB module.
in the secondary chassis
does not have power Restore the power.

Table 5.2 If a CNB module displays PwDS, use this table to troubleshoot the secondary chassis.

If the SRM module And a secondary CNB And a secondary controller Then:
has a: module: has a:
Green OK LED does not display NET ERR Flashing Red OK LED Clear the major fault of the controller.
Solid Red OK LED 1. Cycle the power to the chassis.

2. If the OK LED remains solid red, replace

the controller and flash the controller
with the appropriate revision of
firmware.
displays NET ERR Check all ControlNet taps, connectors, and
terminators for proper connections.
Red OK LED 1. Cycle the power to the chassis.

2. If the OK LED of the SRM module

remains solid red, contact your
Rockwell Automation representative or
local distributor.

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 Maintain and Troubleshoot the System 5-3

Troubleshoot a Failure to • If the steps in this section do not correct the situation, check the
IMPORTANT
Synchronize usage of the CNB modules. See “Adjust CNB Usage” on
page 5-11.
• After you correct the situation, manually synchronize the
controllers. See “Manually Synchronize the Controllers” on
page 5-6.

To determine if a pair of redundant chassis are synchronized, look at

the 1756-CNB/D or -CNBR/D modules in the primary chassis:
Front panel: If: Then: Which means:
Primary CNB PwQS Primary with Synchronized The redundant chassis are
(Qualified) Secondary synchronized.
Look here. PwDS Primary with Disqualified Secondary A problem exists. The redundant
chassis are not synchronized.
PwNS Primary with No Secondary

If the chassis fail to synchronize, look at the 1756-CNB/D or -CNBR/D

modules in the secondary chassis.

Front panel: If the display Then: So check the following:

shows:
Secondary CNB !Cpt The CNB modules in the 1. All CNB modules in each redundant chassis are series D
primary and secondary modules.
chassis do not match in 2. Each CNB module has a partner in the same slot in the other
some way. redundant chassis.
3. Each pair of CNB modules (one in each chassis) is set to the
same node address.
4. All CNB modules in each redundant chassis are valid keepers.
See “Update a Keeper Signature” on page 5-4.
CMPT Some module other than a 1. Each module has a partner in the same slot in the other
CNB module does not redundant chassis.
match between the primary 2. Each pair of controllers (one in each chassis) has the same
and secondary chassis. memory board (e.g., 1756-L55M14).
3. Each module contains compatible firmware.
4. The RSLogix 5000 project is configured for a 1756-L55
ControlLogix5555 controller and redundancy is enabled. See
“Configure the Project for the Controllers” on page 4-2.
5. The Module Configuration window for the 1757-SRM module
does not list any reasons for the failure to synchronize. See
“Check the Recent Synchronization Attempts“ on page 5-5.
DUPL NODE More than one device on 1. No other device on the ControlNet network is set to the address
your ControlNet network is of the CNB modules plus one.
using the same node For example, if the CNB modules are set to 3, no other device
number. should be set to 4.
2. The 1757-SRCx cable is connected to both SRM modules.
NET ERR The ControlNet media is All ControlNet taps, connectors, and terminators are connected.
not completely connected.

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5-4 Maintain and Troubleshoot the System

Update a Keeper Signature

Secondary

If the secondary chassis fails to synchronize, and its CNB module

displays !Cpt, the keeper signature of a CNB module may not match
its partner. This occurs if you schedule the ControlNet network while
!Cpt
the secondary chassis is off or if the CNB module was previously
configured in a different network.

1. Start RSNetWorx for ControlNet software.

42797
2. Has this network been scheduled before?

If: Then:
No A. From the File menu, select New.
B. From the Network menu, select Online.
C. Select your ControlNet network and choose OK.
Yes A. From the File menu, select Open.
B. Select the file for the network and choose Open.
C. From the Network menu, select Online.

3. From the Network menu, choose Keeper Status.

4. 5.

Keeper Capable Node Active Keeper Valid Keeper

offline file N/A N/A
01 NO NO
02 YES YES

4. Make sure the list contains all keeper capable nodes.

5. Make sure that each node has a valid keeper signature.

If the Valid Keeper column Then:

shows:
YES The node has a valid keeper signature.
NO Select the node and choose Update Keeper.

6. Choose Close.

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 Maintain and Troubleshoot the System 5-5

Check the Recent Synchronization Attempts

1. Display RSLinx software.

2. From the Communications menu, choose RSWho.

3. Expand the network until you see the 1757-SRM module in the
primary chassis.

− Workstation
+ Linx Gateways, Ethernet
− AB_KTC-x, ControlNet
− n, 1756-CNB/D
− Backplane, 1756-Ax
xx, 1757-SRM

4. Right-click the 1757-SRM module and choose

Module Configuration.

5. Check the Synchronization tab

a. Click the Synchronization tab.

b. Look here.

If the Result column Then synchronization failed for this reason: So take this corrective action:
shows:
Edit Session in Progress Synchronization failed for any of these reasons: Either:

• Another workstation is editing the project in • Stop the edit session.

the controller. • Untest the edits.
• The project contains test edits. • Close the Nonvolatile Memory Load/Store
• The Nonvolatile Memory Load/Store dialog dialog box.
box of the controller is open.

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Manually Synchronize the After a switchover, you may have to manually synchronize the
controllers because either:
Controllers
• The Auto-Synchronization option is NOT set to Always.
• The controllers failed to synchronize.

To manually synchronize the controllers:

1. Display RSLinx software.

2. From the Communications menu, choose RSWho.

3. Expand the network until you see the 1757-SRM module in the
primary chassis.

− Workstation
+ Linx Gateways, Ethernet
− AB_KTC-x, ControlNet
− n, 1756-CNB/D
− Backplane, 1756-Ax
xx, 1756 module, 1757-SRM

4. Right-click the 1757-SRM module and select

Module Configuration.

5. Click the Synchronization tab.

6. Choose Synchronize Secondary and then choose Yes to confirm.

7. Choose OK.

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8. In the primary chassis, what do the CNB modules display?

Front Panel: If you see: Which means: Then:

PwQg Primary with Synchronizing • Synchronization is in progress.
(Qualifying) Secondary • Continue waiting. It may take several
minutes to synchronize the secondary
Look here.
controller.
PwQS Primary with Synchronized • The secondary controller is synchronized.
(Qualified) Secondary • Skip the remaining steps in this section.
PwDS Primary with Disqualified • The secondary controller is not
Secondary synchronized.
43130
• Go to step 9.

9. Cycle power to the secondary chassis.

10. If the CNB module in the primary chassis fails to display PwQS,
see “Troubleshoot a Failure to Synchronize” on page 5-3.

Optimize Communication If it takes too long to synchronize the secondary chassis or update
your HMI, there may not be enough controller time for unscheduled
communication. In general, unscheduled communication is any type
of communication that you do not configure through the I/O
configuration folder of the controller:

This type of communication: Is:

update I/O data (not including block-transfers) scheduled communication
produce or consume tags
communicate with programming devices unscheduled communication
(e.g., RSLogix 5000 software)
communicate with HMI devices
execute Message (MSG) instructions, including
block-transfers
respond to messages from other controllers
synchronize the secondary controller of a redundant
system
re-establish and monitor I/O connections (such as Removal
and Insertion Under Power conditions); this does not
include normal I/O updates that occur during the execution
of logic.
bridge communications from the serial port of the
controller to other ControlLogix devices via the
ControlLogix backplane

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To improve the speed of unscheduled communication:

If your RSLogix 5000 project contains: Then: See page:

only a continuous task and no other tasks Choose a Greater System Overhead Time 5-8
(This is the default task configuration.) Slice
more than one task (i.e., at least 1 periodic Make All Your Tasks Periodic 5-10
task)

Choose a Greater System Overhead Time Slice

The system overhead time slice specifies the percentage of time

(excluding the time for periodic tasks) that the controller devotes to
unscheduled communication. The controller performs unscheduled
communication for up to 1 ms at a time and then resumes the
continuous task.

The following table shows the ratio between the continuous task and
unscheduled communication at various system overhead time slices:

At this time slice: The continuous tasks runs for: And unscheduled communication
occurs for up to:
10% 9 ms 1 ms
20% 4 ms 1 ms
33% 2 ms 1 ms
50% 1 ms 1 ms

At a system overhead time slice of 20 % (default), unscheduled

communication occurs every 4 ms of continuous task time for 1 ms.

Legend:
Task executes.

Task is interrupted (suspended).

1 ms 1 ms 1 ms 1 ms 1 ms
unscheduled communication
4 ms 4 ms 4 ms 4 ms 4 ms
continuous task

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If you increase the system overhead time slice to 33 %, unscheduled

communication occurs every 2 ms of continuous task time for 1 ms.

1 ms 1 ms 1 ms 1 ms 1 ms 1 ms 1 ms 1 ms
unscheduled communication
2 ms 2 ms 2 ms 2 ms 2 ms 2 ms 2 ms 2 ms 2 ms
continuous task

Enter a System Overhead Time Slice

To change the system overhead time slice:

1.

1. On the Online toolbar, click controller properties button.

2. Click the Advanced tab.

2.

3.

3. Type or select a value for the system overhead time slice.

4. Choose

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Make All Your Tasks Periodic

If the controller contains only a periodic task or tasks, the system

overhead time slice value has no effect. Unscheduled communication
occurs whenever a periodic task is not running.

For example, if your task takes 50 ms to execute and you configure its
update rate to 80 ms, the controller has 30 ms out of every 80 ms for
unscheduled communication.

50 ms 50 ms 50 ms
periodic task
30 ms 30 ms 30 ms
unscheduled communication

If you have multiple tasks, make sure that:

1. The execution time of a highest priority task is significantly less

than its update rate.

2. The total execution time of all your tasks is significantly less than
the update rate of the lowest priority tasks.

For example, in this configuration of tasks:

Task: Priority: Execution time: Rate

1 higher 20 ms 80 ms
2 lower 30 ms 100 ms
total execution time: 50 ms

1. The execution time of the highest priority task (Task 1) is

significantly less than its update rate (20 ms is less than 80 ms).

2. The total execution time of all tasks is significantly less than the
update rate of the lowest priority task (50 ms is less than
100 ms).

This generally leaves enough time for unscheduled communication.

Adjust the update rates of the tasks as needed to get the best trade-off
between executing your logic and servicing unscheduled
communication.

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Adjust CNB Usage For each CNB module in a redundant chassis, keep CPU usage to less
than 75 percent.

• Each redundant CNB module needs enough additional

processing time for redundancy operations.
• At peak operations such as synchronization, redundancy uses an
additional 8 percent (approximately) of the CPU of the CNB
module.
• A total CPU usage that is higher than 75 percent may prevent a
secondary chassis from synchronizing after a switchover.

To reduce the CPU usage of a module, you have these options:

• Change the network update time (NUT) of the ControlNet

network (Typically, increase the NUT to reduce the CPU usage
of a CNB module.)
• Increase the requested packet interval (RPI) of your connections
• Reduce the number of connections to (through) the CNB
• Reduce the number of MSG instructions
• Add another CNB module to each redundant chassis

To get status information about a CNB module, you have these

options:

❑ Use RSLinx Software

❑ Look at the Four Character Display
❑ Send a Message to the CNB Module

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Use RSLinx Software

1. Start RSLinx software.

2. Expand a network until you see your CNB module.

3. Right-click the module and choose Module Statistics.

4. Click the Connection Manager tab.

number of connections
used

CPU usage

42903

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Look at the Four Character Display

On the front of the 1756-CNB/D or -CNBR/D module, the four

character display shows the following information:

For information about a CNB Display: Where:

module:
percent of CPU usage %Cxx xx is the percent of CPU usage. The range for the display is 00 - 99 %.
number of open connections nCxx xx is the number of open connections that are in use by the CNB module.
number of unconnected buffers nUxx xx is the number of unconnected buffers that are in use by the CNB module.
state of the module’s keeper Kpxx xx is the state of the module’s keeper function:
function
If xx is: Then the keeper is:
Ai active network keeper with either:
• invalid keeper information
or
• keeper signature that does not match the keeper signature of the
network
Av active network keeper with:
• valid keeper information
• keeper signature that defines the keeper signature of the network
Ii inactive network keeper with either:
• invalid keeper information
or
• keeper signature that does not match the keeper signature of the
network
Iv inactive network keeper with valid keeper information that matches the
keeper signature of the network
Oi • powering up with invalid keeper information
or
• offline with invalid keeper information
Ov • powering up with valid keeper information that may or may not match
the keeper signature of the network
or
• offline with valid keeper information that may or may not match the
keeper signature of the network
number of times that the Bxnn nn is the number of times that the bandwidth of the module was exceeded (bandwidth
bandwidth of the module was exceeded error) since the module was turned off or reset. You see this information only if
exceeded the count is greater than zero.

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Send a Message to the CNB Module

To use a Message (MSG) instruction to get the CPU usage of a

CNB module, configure the MSG instruction as follows:

On this tab: For this: Type or select:

Configuration Message Type CIP Generic
Service Code 4f
Class name a1
Instance name 8
Attribute name leave blank
Source tag that uses a user-defined data type:

Members of the data type: Tag value:

Name: Data type:
offset DINT 0
size_returned INT 2

Num. Of Elements 6
Destination INT tag in which to store the CPU usage of the CNB module
(0 - 99%.)
Communication Path 1, slot_number

where:

slot_number is the slot number of the CNB module.

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Export the SRM Event Log To export specific events from the SRM event log to a Microsoft Excel
spreadsheet:
to Microsoft® Excel
❑ Export Events to a CSV File
❑ Open and Format the CSV File

Export Events to a CSV File

1. Display RSLinx software.

2. Expand the network until you see the 1757-SRM module in the
primary chassis.

− Workstation
+ Linx Gateways, Ethernet
− AB_KTC-x, ControlNet
− n, 1756-CNB/D
− Backplane, 1756-Ax
xx, 1756 module, 1757-SRM

3. Right-click the 1757-SRM module and select

Module Configuration.

4. Click the Event Log tab.

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6.

5.

5. Select the events that you want to export, as follows:

a. Click the first event that you want to export.
b. Press and hold [Shift] and click the last event that you want to
export.

6. Choose Export Selection.

8.

7.

7. Choose CSV (Comma-Separated Value).

8. Supply a location and file name for the export file.

9. Choose Export.

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Open and Format the CSV File

1. In Microsoft Excel software, open the .CSV file.

2. For the Log Time column, display the Format Cells dialog box.

3. From the Category list, select Custom.

4. In the Type box, enter the following format:

m/d/yyyy h:mm:ss.000

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Configure the The Auto-Synchronization option determines when the 1757-SRM

modules attempt to synchronize the controllers.
Auto-Synchronization
Option
Choose an Auto-Synchronization Option

If you want the SRM modules to: Then choose this Notes:
Auto-Synchronization option:
always try to synchronize the controllers Always (default) This is the typical option.
• always try to synchronize the controllers until Conditional Use this option if you frequently expect to
you manually disqualify the secondary chassis manually toggle in and out of the disqualified
• once you disqualify the secondary chassis, condition. With this option:
never try to synchronize the controllers until you • When you synchronize the
manually synchronize the controllers controllers, the SRM modules try to
keep the controllers synchronized.
• When you disqualify the secondary
chassis, the SRM modules no longer
try to keep the controller
synchronized.
never try to synchronize the controllers Never You can still manually synchronize the
controllers.

Configure the Auto-Synchronization Option

1. Display RSLinx software.

2. From the Communications menu, choose RSWho.

To expand a network one level, do one of − Workstation

the following:
+ Linx Gateways, Ethernet
• Double-click the network.
+ AB_KTC-x, ControlNet
• Select the network and press
the → key.
• Click the + sign.

3. Navigate to the CNB module of the primary chassis. The primary

chassis uses the node to which its rotary switches are set.

− Workstation
+ Linx Gateways, Ethernet
− AB_KTC-x, ControlNet
primary chassis + n, 1756-CNB/D

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4. Expand the CNB module of the primary chassis.

5. Expand the backplane.

− Workstation
+ Linx Gateways, Ethernet
− AB_KTC-x, ControlNet
− n, 1756-CNB/D
− Backplane, 1756-Ax
xx, 1756 module, 1757-SRM

6. Right-click the 1757-SRM module and select

Module Configuration.

7. Click the Configuration tab.

8. Choose the Auto-Synchronization option:

If you want the SRM modules to: Then choose this

Auto-Synchronization option:
always try to synchronize the controllers Always (default)
• always try to synchronize the controllers until Conditional
you manually disqualify the secondary chassis
• once you disqualify the secondary chassis,
never try to synchronize the controllers until you
manually synchronize the controllers
never try to synchronize the controllers Never

9. Choose OK.

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Get System Values You can use a GSV instruction in your ladder logic to get system
values for your redundancy system. You can then display that
information on an HMI screen.

The REDUNDANCY object provides the following status information

about the redundancy system.

For this information: Get this attribute: Data GSV/SSV: Description:

Type:
redundancy status of the ChassisRedundancy INT GSV If: Then:
entire chassis State
16#1 power-up or undetermined
16#2 primary with synchronized secondary
16#3 primary with disqualified secondary
16#4 primary with no secondary
redundancy state of the PartnerChassis INT GSV If: Then:
partner chassis RedundancyState
16#8 synchronized secondary
16#9 disqualified secondary with primary
redundancy status of the ModuleRedundancy INT GSV If: Then:
controller State
16#1 power-up or undetermined
16#2 primary with synchronized secondary
16#3 primary with disqualified secondary
16#4 primary with no secondary
16#6 primary with synchronizing secondary
redundancy state of the PartnerModule INT GSV If: Then:
partner RedundancyState
16#7 synchronizing secondary
16#8 synchronized secondary
16#9 disqualified secondary with primary
results of the compatibility CompatibilityResults INT GSV If: Then:
checks with the partner
controller 0 undetermined
1 no compatible partner
2 fully compatible partner
status of the Qualification INT GSV If: Then:
synchronization InProgress
-1 Synchronization (qualification) is not in progress.
(qualification) process
0 unsupported
1 - 99 For modules that can measure their completion
percentage, the percent of synchronization
(qualification) that is complete.
50 For modules that cannot measure their completion
percentage, synchronization (qualification) is in
progress.
100 Synchronization (qualification) is complete.

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For this information: Get this attribute: Data GSV/SSV: Description:

Type:
keyswitch settings of the KeyswitchAlarm DINT GSV If: Then:
controller and its partner
0 one of the following:
match or do not match
• The keyswitches match.
• No partner is present.
1 keyswitches do not match
position of the keyswitch of PartnerKeyswitch DINT GSV If: Then the keyswitch is in:
the partner
0 unknown
1 RUN
2 PROG
3 REM
status of the minor faults of PartnerMinorFaults DINT GSV This Means this minor fault:
the partner (if the bit:
ModuleRedundancyState
indicates that a partner is 4 problem with an instruction (program)
present) 6 periodic task overlap (watchdog)
9 problem with the serial port
10 low battery
mode of the partner PartnerMode DINT GSV If: Then:
16#0 power up
16#1 program
16#2 run
16#3 test
16#4 faulted
16#5 run-to-program
16#6 test-to-program
16#7 program-to-run
16#8 test-to-run
16#9 run-to-test
16#A program-to-test
16#B into faulted
16#C faulted-to-program
In a pair of redundant PhysicalChassisID INT GSV If: Then:
chassis, identification of a
specific chassis without 0 unknown
regard to the state of the 1 Chassis A
chassis.
2 Chassis B
slot number of the SRMSlotNumber INT GSV
1757-SRM module in this
chassis

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For this information: Get this attribute: Data GSV/SSV: Description:

Type:
Number of DINTs that were LastDataTransfer DINT GSV This attribute is only valid on a primary controller that is
or would have been Size configured for redundancy.
transferred
If: Then this value is the:
a synchronized amount of data that was last
partner is present transferred to the partner, specified in
DINTs
no partner is present amount of data that would have been
last transferred to a synchronized
a disqualified partner
partner, specified in DINTs
is present
Maximum number of DINTs MaxDataTransfer DINT GSV Maximum value of the LastDataTransfer Size attribute
that were or would have Size
been transferred SSV • This attribute is only valid on a primary controller that is
configured for redundancy.
• To reset this value, use an SSV instruction with a
Source value of 0.
If: Then this value is the:
a synchronized maximum amount of data that was
partner is present transferred to the partner, specified in
DINTs
no partner is present maximum amount of data that would
have been last transferred to a
a disqualified partner
synchronized partner, specified in
is present DINTs

For more information on the status information that you can access
with the GSV instruction, see Logix5000 Controllers General
Instructions Reference Manual, publication 1756-RM003.

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EXAMPLE Get system values

The first GSV instruction gets the label of the chassis that is currently the primary chassis
and stores the value in redundant_ID. The second GSV instruction gets the
redundancy state of the controller and stores the value in redundant_state.

GSV GSV
Get System Value Get System Value
Class name REDUNDANCY Class name REDUNDANCY
Instance name ? Instance name ?
Attribute Name PhysicalChassisID Attribute Name ModuleRedundancyState
Dest redundant_ID Dest redundant_state
16#0000_0000 16#0000_0000

42807

Where: Is:
redundant_ID Tag to store the chassis label. The label tells you which chassis is
acting as the primary chassis:

• Data type is DINT.

• Display style is Hex.
redundant_state Tag to store the value of the redundancy state of the controller:

• Data type is DINT.

• Display style is Hex.

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Send a Message to an SRM

Module
IMPORTANT Send only unconnected messages to a 1757-SRM
module.

Leave the Connected check

box clear (unchecked).

You can use ladder logic to perform the following actions:

• initiate a switchover
• disqualify the secondary controller
• synchronize the secondary controller
• set the clock of the SRM module

To send a message to a module:

❑ Configure the 1757-SRM Module

❑ Enter the Message Instruction
❑ Configure the Message Instruction

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Configure the 1757-SRM Module

To send a message to an 1757-SRM module, configure the module to

respond to ladder logic messages:

1. Start RSLinx software.

2. From the Communications menu, choose RSWho.

3. Expand the network until you see the SRM module in the
primary chassis.

− Workstation
+ Linx Gateways, Ethernet
− AB_KTC-x, ControlNet
− xx, 1756-CNB/D
− Backplane, 1756-Ax
xx, 1756 module, 1757-SRM

4. Right-click the 1757-SRM module and select

Module Configuration.

5. Click the Configuration tab.

6. Select the Enable User Program Control check box. This is the
default setting.

7. Choose OK.

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Enter the Message Instruction

1. Open the RSLogix 5000 project.

2. Enter a MSG instruction and associated input instruction (s).

e condition ? MSG
e / Message EN
e Message Control ? ... DN
e ER
e
e
42424

3. In the MSG instruction, type a name for the message control tag
and press the Enter key.

4. In the MSG instruction, right-click the message control tag and

select New tag_name.

e condition ? 5. MSG
e / Type - Unconfigured EN
e Message Control message ... DN
e ER
e 42424

5. Enter message.EN.

where:

message is the message control tag from step 3.

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Configure the Message Instruction

1. In the MSG instruction, click ... .

2. Select a configuration for the message:

Table 5.3 Message to a Module

If you want to: On this tab: For this item: Type or select:
initiate a switchover Configuration Message Type CIP Generic
Service Code 4e
Class name bf
Instance name 1
Attribute name leave blank
Source DINT tag with a value of 1
Num. Of Elements 4
Destination leave blank
Communication Path 1, slot_number

where:

slot_number is the left-hand slot number of the

1757-SRM module.
Connected check box. Leave the Connected check box clear (unchecked). You can
send only unconnected messages to a 1757-SRM module.
disqualify the secondary Configuration Message Type CIP Generic
controller
Service Code 4d
Class name bf
Instance name 1
Attribute name leave blank
Source DINT tag with a value of 1
Num. Of Elements 4
Destination leave blank
Communication Path 1, slot_number

where:

slot_number is the left-hand slot number of the

1757-SRM module.
Connected check box. Leave the Connected check box clear (unchecked). You can
send only unconnected messages to a 1757-SRM module.

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Table 5.3 Message to a Module (Continued)

If you want to: On this tab: For this item: Type or select:
synchronize the secondary Configuration Message Type CIP Generic
controller
Service Code 4c
Class name bf
Instance name 1
Attribute name leave blank
Source DINT tag with a value of 1
Num. Of Elements 4
Destination leave blank
Communication Path 1, slot_number

where:

slot_number is the left-hand slot number of the

1757-SRM module.
Connected check box. Leave the Connected check box clear (unchecked). You can
send only unconnected messages to a 1757-SRM module.
set the clock of the SRM Configuration Message Type CIP Generic
module
Service Code 10
Class name 8b
Instance name 1
Attribute name 1
Source WallClockTime[0]

where:

WallClockTime is a DINT[2] array that stores the

CurrentValue of the WALLCLOCKTIME object.
Num. Of Elements 8
Destination leave blank
Communication Path 1, slot_number

where:

slot_number is the left-hand slot number of the

1757-SRM module.
Connected check box. Leave the Connected check box clear (unchecked). You can
send only unconnected messages to a 1757-SRM module.

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EXAMPLE Set the clock of the 1757-SRM module

When set_time is on, the GSV instruction gets the current value of the WALLCLOCKTIME
object and stores the value in the WallClockTime array (64 bits). The message instruction
then sends the value to the SRM module.

set_time GSV msg_set_time.EN

Get System Value /
Class name WALLCLOCKTIME
Instance name
Attribute Name CurrentValue
Dest WallClockTime[0]
0

MSG
Type - CIP Generic EN
Message Control msg_set_time ... DN
ER
42807

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Store or Load a Project Nonvolatile memory lets you keep a copy of your project on the
controller.
Using Nonvolatile Memory
Term: Description:
nonvolatile memory Memory of the controller that retains its contents while the controller is without power or
a battery.
store To copy a project to the nonvolatile memory of the controller. This overwrites any project
that is currently in the nonvolatile memory.
load To copy a project from nonvolatile memory to the user memory (RAM) of the controller.
This overwrites any project that is currently in the controller.

In a redundant system, you can store or load a project only while the
secondary chassis is disqualified.

If you want to do this in a Do this:

redundant system:
Store a Project 1. Does the primary controller already contain the project that you want to store?
If: Then:
yes Go to step 2.
no Download the project to the primary controller.

2. Place the primary controller in program mode (program or remote program).

3. In the Module Configuration properties for one of the 1757-SRM modules, set the
Auto-Synchronization option = Conditional.
4. Disqualify the secondary chassis.
5. In the primary controller, store the project.
For step-by-step procedures on how to store a project, see Logix5000 Controllers Common
Procedures, publication 1756-PM001.
6. Synchronize the controllers.
7. Initiate a switchover.
8. Disqualify the new secondary chassis.
9. In the new primary controller, store the project.
10. Synchronize the controllers.
11. In the Module Configuration properties for one of the 1757-SRM modules, set the
Auto-Synchronization option = the desired option.
Load a Project—User Initiated 1. Disqualify the secondary chassis.
2. Go online to the primary controller.
3. In the primary controller, load the project.
For step-by-step procedures on how to load a project, see Logix5000 Controllers Common
Procedures, publication 1756-PM001.
4. Synchronize the controllers.
Load a Project—On Power Up This Load Image option works the same as in a non-redundant system. When the controller loads
a project on power up, it does so before it activates the redundancy feature.
Load a Project—On Corrupt Memory This Load Image option works the same as in a non-redundant system. When the controller loads
a project due to corrupt memory, it does so before it activates the redundancy feature.

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Update a Module Use the following steps to upgrade the revision of your redundant
modules. This procedure minimizes the time your process is down for
the upgrade.

IMPORTANT Do not connect your computer to the ControlNet

network via the network access port on a CNB
module in the primary chassis. When you turn off
power to the chassis, you will lose access to the
network.

To update a module:Disqualify the Secondary Chassis

❑ Upgrade the Required Firmware of the Secondary Chassis

❑ Make the Secondary Controller the New Primary Controller
❑ Upgrade the Other Redundant Chassis
❑ Change the Auto-Synchronization Option to ALWAYS

Disqualify the Secondary Chassis

1. Start RSLinx software.

2. Find the SRM module in the secondary chassis.

− Workstation
+ Linx Gateways, Ethernet
− AB_KTC-x, ControlNet
+ xx, 1756-CNB/D
The secondary chassis is one
node greater than the primary − xy, 1756-CNB/D
chassis.
− Backplane, 1756-Ax
xx, 1756 module, 1757-SRM

Publication 1756-UM523C-EN-P - June 2003

5-32 Maintain and Troubleshoot the System

3. Right-click the 1757-SRM module and select

Module Configuration.

4. Click the Configuration tab.

5. Select NEVER.

6. Choose Apply and then Yes to confirm.

7. Click the Synchronization tab.

8. Choose Disqualify Secondary.

9. Choose Yes to confirm.

Upgrade the Required Firmware of the Secondary Chassis

See theControlLogix Controller and Memory Board Installation

Instructions, publication 1756-IN101.

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 Maintain and Troubleshoot the System 5-33

Make the Secondary Controller the New Primary Controller

1. Start RSLogix 5000 software.

2. Download the project to the secondary controller.

3. When it is safe to stop the control of your system, change the

primary controller to Program Mode.

4. Turn off power to the primary chassis.

5. Go to the 1757-SRM properties of the secondary chassis.

42808

6. Choose Become Primary.

7. In RSLogix 5000 software, go online to the new primary

controller.

8. The controller is faulted. When a disqualified secondary

controller becomes a primary controller, the controller
experiences a major fault.

9. From the Communications menu, choose Clear Faults.

10. To start control of the process, from the Communications menu,

choose Run Mode.

Upgrade the Other Redundant Chassis

1. Turn on power to the other redundant chassis.

2. Upgrade the required firmware of the chassis.

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5-34 Maintain and Troubleshoot the System

Change the Auto-Synchronization Option to ALWAYS

1. Go to RSLinx software.

2. Find the SRM module in the primary chassis and open the
properties of the module.

3. On the Configuration tab, change the Auto-Synchronization

Option to ALWAYS.

4. Choose OK.

Publication 1756-UM523C-EN-P - June 2003

 Appendix A

Develop the Bill of Materials

Redundant Controller The ControlLogix redundancy system requires the following hardware
for your controllers:
Chassis
✔ Qty Item Cat number
2 chassis 1756-A4, -A7, -A10, -A13, or -A17
2 power supply 1756-PA72, -PB72, -PA75, or -PB75
2 controller 1756-L55M13, -L55M14, -L55M16, -L55M23, or
-L55M24
2 ControlNet bridge 1756-CNB/D or -CNBR/D
module
2 redundancy module 1757-SRM
1 fiber optic cable 1757-SRC1, -SRC3, -SRC10, -SRC50, or -SRC100

Additional Materials You also need the following materials. The actual items depend on the
design and lay-out of your system.

✔ Qty Item Cat number Notes

chassis or DIN as required for your I/O For ControlLogix chassis, redundant power supplies are available as an
rails modules option:

• For a redundant power supply kit, order catalog number 1756-PAR or

1756-PBR.
• Each kit contains two redundant power supplies, cable, and adapter.
ControlNet as required for your • You need an adapter for each remote chassis or rail.
adapters chassis or DIN rail
• If you are using a redundant ControlNet network, order the
redundant (R) version of each adapter.

• You need at least two ControlNet nodes in addition to the CNB

modules in the redundant chassis pair.
ControlNet tap 1786-TPS, -TPR, -TPYS, If you are using a redundant ControlNet network, you need two taps for each
or -TPYR device on your ControlNet network.
RG-6 coaxial 1786-RG6 or -RG6F
cable
terminator 1786-XT You need 2 terminators for each ControlNet segment.

1 Publication 1756-UM523C-EN-P - June 2003

A-2 Develop the Bill of Materials

✔ Qty Item Cat number Notes

RSLogix 5000 • For catalog numbers, see the ControlLogix Selection Guide,
software publication 1756-SG001
RSLinx Lite • For compatible revisions of firmware and software, see the
software ControlLogix Redundancy System Release Notes, publication
1756-RN582.
RSNetWorx for
ControlNet
software

Publication 1756-UM523C-EN-P - June 2003

 Appendix B

Convert an Existing System to Redundancy

Introduction If you are adding redundancy to an existing system, follow these

suggestions:

• If you change the node number of a CNB module, you may

affect messages, tags, or listen-only connections in other
devices. Choose node numbers that have the least impact on
existing communications.
• If your existing system contains local I/O modules, you still
need two additional chassis.
– A redundant system can use only I/O that is in a remote
chassis (i.e., not in the same chassis as the controller).
– We recommend that you move the existing 1756-L55Mxx
controller from the original chassis and place it in a redundant
chassis.

Convert Local Modules to If you are converting an existing system to a redundant system:
Remote Modules And the system: Then:
contained only I/O modules that You do not have to change the I/O configuration of
were not in the same chassis as the controller.
the controller
contained local I/O modules Use the procedures in this section to convert the
configuration of local modules to remote modules.

To convert a local module to a remote module:

❑ Re-Configure the Local I/O Modules

❑ Replace Local I/O Tags
❑ Replace any Aliases to Local I/O Tags

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B-2 Convert an Existing System to Redundancy

Re-Configure the Local I/O Modules

1. If you have not already done so, add the CNB module of the
remote chassis to the I/O configuration of the controller. See the
ControlLogix System User Manual, publication 1756-UM001.

− I/O Configuration

[x] 1756-xxx name_of_local_module Cut local I/O modules from here.

− [x] 1756-CNB/x name_of_local_CNB

z [x] 1756-CNB/x name_of_remote_CNB Paste the I/O modules

here.

2. In the controller organizer, cut the modules from the local I/O
configuration and paste them into the remote CNB module. Cut
and paste the following modules:
• I/O
• 1756-DHRIO
• 1756-DNB
• 1756-ENET or -ENB
• 1756-MVI

Replace Local I/O Tags

1. Open a routine. If a routine is already open, click within the

routine to activate the window.

Publication 1756-UM523C-EN-P - June 2003

 Convert an Existing System to Redundancy B-3

2. Press the Ctrl + H keys (replace).

42804

3. Type Local.

4. Type the name of the CNB module that is in the remote chassis.

5. Select All Routines.

6. Choose Find Within >>.

42805
8

7. Select Ladder Diagram.

8. Check Instruction Operands.

9. Choose Replace All.

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B-4 Convert an Existing System to Redundancy

The Search Results tab displays the changes to the logic.

10. Choose Close.

The following example shows the results of replacing “Local” with

“chassis_c”.

Replacing "Local" with "chassis_c"...

EXAMPLE

Searching through MainProgram - MainRoutine...

Replaced: Rung 0, XIC, Operand 0: XIC(Local:16:I.Data.0)

Replaced: Rung 0, OTE, Operand 0: OTE(Local:2:O.Data.0)

Replaced: Rung 1, XIC, Operand 0: XIC(Local:16:I.Data.1)

Replaced: Rung 1, OTE, Operand 0: OTE(Local:2:O.Data.1)

Replaced: Rung 2, XIC, Operand 0: XIC(Local:16:I.Data.2)

Replaced: Rung 2, OTE, Operand 0: OTE(Local:2:O.Data.2)

Replaced: Rung 8, OTE, Operand 0: OTE(Local:15:O.CommandRegister.Run)

Complete - 7 occurrence(s) found, 7 occurrence(s) replaced.

Replace any Aliases to Local I/O Tags

Are any of your tags an alias for an I/O device that was previously in
a local chassis?

If: Then:
Yes Go to step 1.
No Skip this procedure.

1. From the Logic menu, choose Edit Tags.

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 Convert an Existing System to Redundancy B-5

2. Press the Ctrl + H keys (replace).

6
42815

3. Type Local.

4. Type the name of the CNB module that is in the remote chassis.

5. Select All Tags.

6. Choose Find Within >>.

7 42815

7. Check Alias.

8. Choose Replace All.

9. Choose Close.

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B-6 Convert an Existing System to Redundancy

Notes:

Publication 1756-UM523C-EN-P - June 2003

 Index

A conversion
array 4-11 to redundant system B-1
auto-synchronization 5-18 crossload 1-4, 1-5

B D
Basic Operation 1-1 data
bill of materials A-1 crossload 1-5
integrity 4-15
BOM A-1
organize 4-11
BOOL 4-11 data type
BSL instruction 4-15 recommendations 4-10, 4-11
BSR instruction 4-15 DeviceNet network
design 1-7, 2-4
C DINT 4-11
chassis disqualified
install 3-4 overview 1-4
CNB module disqualify
4 character display 5-13 secondary chassis 5-31
connection 2-6 download 3-12
install 3-5
node assignment 2-7 E
requirements 2-3
estimate program scan time 4-9
statistics 5-11
usage 5-11 EtherNet/IP network
communication design 1-7, 2-4
optimize 5-7 event log
connection 2-6 export 5-15
consumed tag export
configure 4-7 event log 5-15
controller
connection 2-6 F
disqualify secondary 5-31 FFU instruction 4-15
download project 3-12 firmware
install 3-5
update 3-9, 5-31
nonvolatile memory 5-30
periodic task 5-10
program scan time 4-9, 4-10 G
project 4-1 Get System Value instruction 5-20
requirements 2-3 GSV instruction 5-20
synchronize 3-10, 5-6
system overhead time slice 5-8
watchdog time 4-20 H
ControlNet network HMI
addresses 1-6 configure tags 4-8
general lay-out 2-2 design recommendations 2-2
keeper signature 3-16, 5-4 optimize communication 5-7
node assignments 2-7
NUT 2-9
redundant media 2-5 I
schedule 3-13 I/O
ControlNet node addresses 1-6 configure 4-6

Publication 1756-UM523C-EN-P - June 2003

2 Index

convert local to remote B-1 minimize 4-10

placement 1-7, 2-4, 3-8 overview 1-5
redundant power supplies 2-6 project
import create and maintain 4-1
event log 5-15 download 3-12
initiate switchover 3-18 load 5-30
install store 5-30
system components 3-1
INT 4-10, 4-11 Q
qualify. See synchronize
K
keeper signature R
check 3-16
update 5-4 REAL 4-11
REDUNDANCY object 5-20
remote I/O network
L design 1-7, 2-4
load a project from nonvolatile memory requested packet interval 4-6
5-30 RIO network
design 1-7, 2-4
M
message S
send to SRM module 5-24 scan time. See program scan time, task
Message instruction 4-8 scan time
Microsoft Excel schedule a ControlNet network 3-13
import event log 5-15 SINT 4-10, 4-11
MSG instruction 4-8 SRM module
auto-synchronization 5-18
configure 5-25
N disqualify secondary 5-31
NAP 1-3, 3-1 export event log 5-15
network access port initiate switchover 3-18
restrictions 1-3, 3-1 install 3-5
network update time 2-9 send message to 5-24
nonvolatile memory synchronization status 3-18
load a project 5-30 synchronize controllers 5-6
store a project 5-30 store a project to nonvolatile memory
NUT. See ControlNet network 5-30
switchover
causes 1-2
P data integrity 4-15
PanelView terminal diagnose cause 5-2
design recommendations 2-2 initiate 3-18
periodic task 5-10 test 3-17
power supplies time for 2-11
redundant 2-6 synchronize
produced tag controllers 5-6
configure 4-7 diagnose failure 3-18
program overview 1-4
number of 4-10 status 3-18
program scan time 4-9 synchronize controllers 3-10

Publication 1756-UM523C-EN-P - June 2003

 Index 3

system information switchover 3-17

get 5-20
system overhead time slice 5-8
U
update firmware 3-9, 5-31
T user-defined data type 4-11
task
number of 5-10
watchdog time 4-20
W
task scan time watchdong time 4-20
determine 4-22 workstation
test connect to a NAP 1-3, 3-1

Publication 1756-UM523C-EN-P - June 2003

4 Index

Publication 1756-UM523C-EN-P - June 2003

 Glossary

connection

A communication link between two devices, such as between a

controller and an I/O module, PanelView terminal, or another
controller. You indirectly determine the number of connections the
controller uses by configuring the controller to communicate with
other devices in the system. Connections are allocations of resources
that provide more reliable communications between devices than
unconnected messages. See direct connection, rack optimization
connection.

consumed tag

A tag that receives the data that is produced (broadcast) by another

controller. Logix5000 controllers can produce and consume tags over
an EtherNet/IP network, a ControlNet network, or a ControlLogix
backplane. See produced tag.

crossload

The transfer of any or all of the contents of the primary controller to

the secondary controller. This could be updated tag values, force
values, online edits, or any other information about the project. A
crossload occurs initially when the controllers synchronize and then
repeatedly as the primary controller executes its logic.

direct connection

A direct connection is a real-time, data transfer link between the

controller and an I/O module. The controller maintains and monitors
the connection between the controller and the I/O module. Any break
in the connection, such as a module fault or the removal of a module
while under power, causes the controller to set fault status bits in the
data area associated with the module. See connection, rack
optimization connection.

disqualified

Indicates that the secondary control has failed to synchronize with the
primary controller. If a secondary controller is disqualified, it is unable
to take over control of the machine or process. You also have the
option of manually disqualifying a secondary controller.

load

To copy a project from nonvolatile memory to the user memory

(RAM) of the controller. This overwrites any project that is currently in
the controller. See nonvolatile memory, store.

1 Publication 1756-UM523C-EN-P - June 2003

Glossary 2

NAP

See network access port (NAP).

network access port (NAP)

A port on a ControlNet device that lets you connect another device to

a ControlNet network.

network update time (NUT)

The repetitive time interval in which data is sent over an EtherNet/IP

or ControlNet network.

nonvolatile memory

Memory of the controller that retains its contents while the controller
is without power or a battery. See load, store.

NUT

See network update time (NUT).

primary chassis

The chassis that contains the primary controller.

primary controller

The controller that is currently controlling the machine or process.

produced tag

A tag that a controller is making available (broadcasting) for use by

other controllers. See consumed tag.

rack optimization connection

For digital I/O modules, you can select rack optimization

communication. A rack optimized connection consolidates connection
usage between the controller and all the digital I/O modules on a rack
(or DIN rail). Rather than having individual, direct connections for
each I/O module, there is one connection for the entire rack (or DIN
rail). See connection, direct connection.

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 Glossary 3

requested packet interval (RPI)

When communicating over a network, this is the maximum amount of

time between subsequent production of input data.

• Typically, this interval is configured in microseconds.

• The actual production of data is constrained to the largest
multiple of the network update time that is smaller than the
selected RPI.
• Use a binary multiple of the network update time (NUT). The
binary multipliers are: 1, 2, 4, 8, 16, 32, 64, and 128.

For example, if the NUT is 5 ms, use an RPI of 5, 10, 20, 40 ms,
etc.

See network update time (NUT).

RPI

See requested packet interval (RPI).

secondary chassis

The chassis that contains the secondary controller.

secondary controller

The controller that is standing by to take control of the machine or

process.

SMAX

In a ControlNet network, the maximum scheduled address. The

greatest node number to use scheduled communications on a
ControlNet network.

store

To copy a project to the nonvolatile memory of the controller. This

overwrites any project that is currently in the nonvolatile memory.
See load, nonvolatile memory.

switchover

Transfer of control from the primary controller to the secondary

controller. After a switchover, the controller that takes control
becomes the primary controller. Its partner controller (the controller
that was previously the primary controller) becomes the secondary
controller.

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Glossary 4

synchronize

The process that readies a secondary controller to take over control if

a failure occurs in the primary chassis. During synchronization, the
1757-SRM modules checks that the partner modules in the redundant
chassis pair are compatible with each other. The SRM module also
crossloads (transfers) the content of the primary controller to the
secondary controller. Synchronization occurs when the secondary
chassis powers up. It may also occur at other times.

system overhead time slice

Specifies the percentage of time (excluding the time for periodic

tasks) that the controller devotes to unscheduled communication.
Unscheduled communication includes:

• communicate with programming and HMI devices (such as

RSLogix 5000 software)
• respond to messages
• send messages, including block-transfers
• re-establish and monitor I/O connections (such as RIUP
conditions); this does not include normal I/O communications
that occur during program execution
• bridge communication from the serial port of the controller to
other ControlLogix devices via the ControlLogix backplane
• synchronize the secondary controller of a redundant system

The controller performs unscheduled communication for up to 1 ms

at a time. The following table shows the ratio between the continuos
task and unscheduled communication at various system overhead
time slices:

At this time slice: The continuous tasks runs for: And unscheduled communication
occurs for up to:
10% 9 ms 1 ms
20% 4 ms 1 ms
33% 2 ms 1 ms
50% 1 ms 1 ms

UMAX

In a ControlNet network, the maximum unscheduled address. The

greatest node number that you will use on a ControlNet network.

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 Glossary 5

watchdog

Specifies how long a task can run before triggering a major fault.

• Each task has a watchdog timer that monitors the execution of

the task.
• A watchdog time can range from 1 ms to 2,000,000 ms (2000
seconds). The default is 500 ms.
• The watchdog timer begins to time when the task is initiated and
stops when all the programs within the task have executed.
• If the task takes longer than the watchdog time, a major fault
occurs. The time includes interruptions by other tasks.

Publication 1756-UM523C-EN-P - June 2003

Glossary 6

Notes:

Publication 1756-UM523C-EN-P - June 2003

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