Logix5555TM ControlNET Redundancy Module

POWER
RUN I/O

RS232
A#01 PRIM

ControlLogix
BAT OK
CHA CHB OK PRI COM OK

RUN REM PROG

A-B
Quality
Allen-Bradley

Redundancy

Logix5555 TM ControlNET Redundancy Module

POWER
RUN I/O

RS232
A#02 SYNC
BAT OK
CHA CHB OK PRI COM OK
RUN REM PROG

A-B
Quality
Allen-Bradley

1
 Main Redundancy Features
• Optimized for availability of control.
• Absolutely no user programming required to implement.
• Bumpless switchover guaranteed for any outputs controlled by logic
in the highest priority task.
• Switchover within approximately 100 msec.
• Works with standard Logix5555 controllers and ControlNet Bridges
(Series D or higher).
• Switchovers are transparent to any devices networked to the
redundant controller chassis.
• Transparent cross-load of programs from primary to secondary
controllers.
• On-line workstation configuration/commands/edits to primary are
automatically forwarded to secondary.
• User can choose to cancel or resume ‘test edits’ at switchover.

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Building a Typical Redundant System
1. Start with a standard ControlLogix chassis.
A-B
Logix5555™

RUN I/O

RS232
ControlNET

A#01 PRIM
Redundancy Module
2. Add 1 or more Logix5555 processors.
Quality
Allen-Bradley BAT OK

RUN REM PROG

CHA CHB OK PRI COM OK

3. Add 1 or more ControlNet Bridges (Series D).

4. Add 1 System Redundancy Module.
5. Set up an identical second controller chassis.
6. Cable the SRMs together.
7. Add I/O, operator interfaces, and so forth to the
ControlNet network(s).

Logix5555™ ControlNET Redundancy Module

RUN I/O
A-B RS232 A#01 PRIM
Quality
Allen-Bradley BAT OK

CHA CHB OK PRI COM OK

RUN REM PROG

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 Other Redundant Architecture
Considerations
• Only Logix5555’s, ControlNet Bridges, and a single System
Redundancy Module can be placed in a redundant controller chassis.
– All I/O must be remote from the redundant controller chassis.
– To connect to other networks, bridge through another ControlLogix
chassis.
Ethernet
Logix ControlNET Redundancy Module
RUN 5555 I/O
A-B ™ RS232 A# P
Allen-Bradley
Quality
BAT OK
01 R
CHA CHB OK PRI COM OK
I
RUN REM PROG
M

A-B
Allen-Bradley
Quality
RUN

BAT
Logix
5555 I/O

OK
ControlNET Redundancy Module

™ RS232 A#
01
P
R
ControlNet
CHA CHB OK PRI COM OK
I
RUN REM PROG
M

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 Logix5555 Controller
• New CPU ASIC
– Provides alternative memory parity encoding method so
that higher density commercial memory may be used.
– New memory change detection algorithms for
Redundancy.
• New circuitry to support new 1.5, 3.5, and 7.5 Mbyte
memory cards.
• Increased Performance
– Faster Flash-Memory to increase operating system
performance.
– Movement of Floating Point library to RAM for higher
performance (30% faster than L1).
• Hardware changes to support ControlLogix
redundancy.
• New Real Time Clock (RTC) chip with increased
accuracy.
• In redundancy, data is buffered in the secondary
controller, so twice as much data memory space is
required.
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ControlNet allows transparent switchovers
• The 1756-CNB Series D has added the
necessary hardware and firmware changes to
support ControlLogix redundancy.
• You set the same ControlNet address on the
rotary switches of the primary and secondary
CNB’s.
– The primary CNB will use that address, and the
secondary CNB will automatically use the next
higher address.
• On a switchover, the CNB’s automatically swap
addresses.
– Any external ControlNet devices will simply
continue to communicate with the new primary
controller.
– ControlLogix redundancy works transparently with
1756 I/O, Flex I/O, drives, operator interfaces, or
any other Rockwell or third-party devices which
can communicate to a Logix5555 over ControlNet.
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 System Redundancy Module
• The 1757-SRM provides the high speed Redundancy Module

data transfers between the primary and PRIM

secondary chassis and arbitrates PRI COM OK

primary/secondary chassis status.

• Two slot module
• Only one SRM per chassis needed.
– We will test with up to four Logix5555
processors per chassis.
• A fiber optic cable connects the primary
and secondary SRM’s.
– 1757-SRC1, SRC3, or SRC10 (1, 3, or 10
meter lengths)

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 1757-SRM Configuration
• The 1757-SRM module will be configured from RSLinx instead of
RSLogix 5000.
– Allows one 1757-SRM to support multiple Logix5555 controllers.
– Similar to how DHRIO and ENET modules are configured using RSLinx 2.2.

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 SRM Dialog Module Info Tab
Provides identification of the Provides the general status of
module. the module.

1757-SRM REDUNDANCY MODULE

Identifies the
current
redundancy
state of this
chassis. This is
visible from
every tab on the Chassis_B: Primary with Qualified
dialog. Secondary

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 SRM Dialog Configuration Tab
Select when you want a disqualified secondary chassis
to automatically attempt synchronization.
• Always
• Never
• Conditional - Auto-synchronization enabled on Lets you specify whether this
a Synchronize Secondary command and chassis should be referred to as
disabled on a Disqualify Secondary command. Chassis A or Chassis B.

Select whether
programmed messages
from a Logix5555 are
allowed to trigger
redundancy
commands (initiate
switchover, disqualify
secondary, etc.)

Set the date and time

to be used in the
SRM event log.
Chassis_B: Primary with Qualified
Secondary

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 SRM Dialog Synchronization Tab
Issues a manual Issues a manual Issues a manual
command to switch Issues a manual
command to attempt command to command allowing a
to synchronize the disqualify the control to the
secondary chassis. disqualified
secondary chassis to secondary chassis to secondary chassis
make it available for make it unavailable This can be used to
test the redundant with no partner to
switchover. for switchover. take control.
system.
1757-SRM REDUNDANCY MODULE

Shows the result of

the last four
synchronization
attempts of the
redundant system.

Chassis_B: Primary with Qualified

Secondary

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 SRM Dialog Chassis Profile Tab
• Shows the current state of all the modules in this
redundant controller chassis. Shows the
Shows the Shows the state of compatibility
Shows the progress
secondary’s the modules between the
of synchronization
readiness to take (startup, faulted, primary and
in percent.
control. etc). secondary module.
1757-SRM REDUNDANCY MODULE

Chassis_B: Primary with Qualified

Secondary

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 SRM Dialog Event Log Tab
• This dialog shows the history of the past 10 events.
• Events that are logged include synchronizations,
switchovers, etc.
• This information is stored on the SRM module.
1757-SRM REDUNDANCY MODULE

Chassis_B: Primary with Qualified

Secondary

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 No programming required
• A primary Logix5555 automatically determines what data changes
during its scan and automatically sends that data to its secondary
Logix5555. You don’t have to program messages or even specify
certain data areas to transfer. It all just happens automatically.

You just select a single

checkbox on the
controller properties
dialog to enable
redundancy.

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 Other Controller Properties Options
Allows you to specify whether you want test
edits to remain in effect after a switchover.
This is useful for online edit changes.

Lets you specify how much of

the unused memory will be
This allocated for adding data online
enables versus adding program online.
redundancy.

Here you can see the status of this

controller chassis and this
controller.

Here you can see the status of this

controller’s redundant partner.

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Automatic cross-loading of programs

Logix5555™ ControlNET Redundancy Module

• You only have
to download
RUN I/O
A-B RS232 A#01 PRIM
Quality
Allen-Bradley BAT OK

CHA CHB OK PRI COM OK

RUN REM PROG

your program
to the primary
controller.
The system
will
Logix5555™ ControlNET Redundancy Module

A-B
Quality
Allen-Bradley
RUN

BAT

RUN
I/O

RS232

OK

REM PROG
A#01

CHA CHB OK
PRIM

PRI COM OK
automatically
cross-load the
primary’s
program to the
secondary
controller.
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 Bumpless Switchovers
• The secondary controller is synchronized with the
primary to provide a bumpless switchover for any
outputs controlled by logic in the highest priority
task:
– Primary notifies secondary when user tasks start.
– Primary notifies secondary when programs complete &
provide a complete data ‘snapshot’.
• Secondary doesn’t execute programs, but follows along,
pending at each program start.
• Incomplete transfers are ‘quarantined’ on secondary until
complete.
– At switchover, the new primary rolls back to the
beginning of currently executing programs using ‘last
good’ data snapshot.
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ControlLogix Redundant Power Supply
1756-PA75R / -PB75R
Power Supplies
• 85 - 265 VAC and 19 - 32 VDC
Versions
• Panel mount (1756-A4 footprint -
6.9" H x 5.7" W x 5.4" D)
• Px75 equivalent capacity

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

1756-PSCA
Chassis Adapter Module
• Passive device funnels power
to backplane
• Series B chassis only
Failure Annunciation
• Normally Open solid state relay on each supply
• Wire to any input module
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