1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for...
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Transcript of 1 ControlLogix Redundancy. Rockwell Automation Confidential2 Main Redundancy Features Optimized for...
1
POWERRedundancy Module
PRI COM OK
PRIM
POWERRedundancy Module
PRI COM OK
SYNC
ControlNET
CHA CHB OK
A#01
RUN REM PROG
Logix5555TM
RUN
OK
RS232
BAT
I/O
RUN REM PROG
Logix5555TM
RUN
OK
RS232
BAT
I/O
ControlNET
CHA CHB OK
A#02
Allen-BradleyQuality
A-B
Allen-BradleyQuality
A-B ControlLogix Redundancy
Rockwell Automation Confidential
2
Main Redundancy Features
• Optimized for availability of control.• Absolutely no user programming required to implement.• Bumpless switchover guaranteed for any outputs controlled by logic in
the highest priority task.• Switchover within approximately 100 msec.• Works with standard Logix5555 controllers and ControlNet Bridges
(Series D or higher).• Switchovers are transparent to any devices networked to the redundant
controller chassis.
• Transparent cross-load of programs from primary to secondary
controllers.
• On-line workstation configuration/commands/edits to primary are
automatically forwarded to secondary.
• User can choose to cancel or resume ‘test edits’ at switchover.
Rockwell Automation Confidential
3
Building a Typical Redundant System
Allen-BradleyA-BQuality
ControlNET
CHA CHB OK
A#01
Redundancy Module
PRI COM OK
PRIM
RUN REM PROG
Logix5555™
RUN
OK
RS232
BAT
I/O 2. Add 1 or more Logix5555 processors.3. Add 1 or more ControlNet Bridges (Series D).4. Add 1 System Redundancy Module.5. Set up an identical second controller chassis.6. Cable the SRMs together.7. Add I/O, operator interfaces, and so forth to the
ControlNet network(s).
1. Start with a standard ControlLogix chassis.
Allen-BradleyA-BQuality
ControlNET
CHA CHB OK
A#01
Redundancy Module
PRI COM OK
PRIM
RUN REM PROG
Logix5555™
RUN
OK
RS232
BAT
I/O
Rockwell Automation Confidential
4
Other Redundant Architecture Considerations
• Only Logix5555’s, ControlNet Bridges, and a single System Redundancy Module can be placed in a redundant controller chassis.– All I/O must be remote from the redundant controller chassis.
– To connect to other networks, bridge through another ControlLogix chassis.
Allen-BradleyA-BQuality
ControlNET
CHA CHB OK
A#01
Redundancy Module
PRI COM OK
PRIM
RUN REM PROG
Logix5555
™RUN
OK
RS232
BAT
I/O
Allen-BradleyA-BQuality
ControlNET
CHA CHB OK
A#01
Redundancy Module
PRI COM OK
PRIM
RUN REM PROG
Logix5555
™RUN
OK
RS232
BAT
I/O ControlNet
Ethernet
Rockwell Automation Confidential
5
Logix5555 Controller• New CPU ASIC
– Provides alternative memory parity encoding method so that higher density commercial memory may be used.
– New memory change detection algorithms for Redundancy.
• New circuitry to support new 1.5, 3.5, and 7.5 Mbyte memory cards.
• Increased Performance– Faster Flash-Memory to increase operating system
performance.– Movement of Floating Point library to RAM for higher
performance (30% faster than L1).
• Hardware changes to support ControlLogix redundancy.
• New Real Time Clock (RTC) chip with increased accuracy.
• In redundancy, data is buffered in the secondary controller, so twice as much data memory space is required.
Rockwell Automation Confidential
6
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.
Rockwell Automation Confidential
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System Redundancy Module
• The 1757-SRM provides the high speed data transfers between the primary and secondary chassis and arbitrates primary/secondary chassis status.
• Two slot module• Only one SRM per chassis needed.
– We will test with up to four Logix5555 processors per chassis.
• A fiber optic cable connects the primary and secondary SRM’s.– 1757-SRC1, SRC3, or SRC10 (1, 3, or 10
meter lengths)
Redundancy Module
PRI COM OK
PRIM
Rockwell Automation Confidential
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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.
Rockwell Automation Confidential
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SRM Dialog Module Info Tab
Chassis_B: Primary with QualifiedSecondary
1757-SRM REDUNDANCY MODULE
Provides identification of the module.
Provides identification of the module.
Provides the general status of the module.
Provides the general status of the module.
Identifies the current
redundancy state of this
chassis. This is visible from
every tab on the dialog.
Identifies the current
redundancy state of this
chassis. This is visible from
every tab on the dialog.
Rockwell Automation Confidential
10
SRM Dialog Configuration Tab
Chassis_B: Primary with QualifiedSecondary
Select when you want a disqualified secondary chassis to automatically attempt synchronization.
• Always• Never• Conditional - Auto-synchronization enabled on
a Synchronize Secondary command and disabled on a Disqualify Secondary command.
Select when you want a disqualified secondary chassis to automatically attempt synchronization.
• Always• Never• Conditional - Auto-synchronization enabled on
a Synchronize Secondary command and disabled on a Disqualify Secondary command.
Lets you specify whether this chassis should be referred to as
Chassis A or Chassis B.
Lets you specify whether this chassis should be referred to as
Chassis A or Chassis B.
Select whether programmed messages from a Logix5555 are
allowed to trigger redundancy
commands (initiate switchover, disqualify
secondary, etc.)
Select whether programmed messages from a Logix5555 are
allowed to trigger redundancy
commands (initiate switchover, disqualify
secondary, etc.)
Set the date and time to be used in the SRM event log.
Set the date and time to be used in the SRM event log.
Rockwell Automation Confidential
11
SRM Dialog Synchronization Tab
Chassis_B: Primary with QualifiedSecondary
1757-SRM REDUNDANCY MODULE
Issues a manual command to attempt to synchronize the
secondary chassis to make it available for
switchover.
Issues a manual command to attempt to synchronize the
secondary chassis to make it available for
switchover.
Issues a manual command to
disqualify the secondary chassis to make it unavailable
for switchover.
Issues a manual command to
disqualify the secondary chassis to make it unavailable
for switchover.
Issues a manual command to switch
control to the secondary chassis. This can be used to test the redundant
system.
Issues a manual command to switch
control to the secondary chassis. This can be used to test the redundant
system.
Issues a manual command allowing a
disqualified secondary chassis with no partner to
take control.
Issues a manual command allowing a
disqualified secondary chassis with no partner to
take control.
Shows the result of the last four
synchronization attempts of the
redundant system.
Shows the result of the last four
synchronization attempts of the
redundant system.
Rockwell Automation Confidential
12
SRM Dialog Chassis Profile Tab
Chassis_B: Primary with QualifiedSecondary
1757-SRM REDUNDANCY MODULE
Shows the progress of synchronization
in percent.
Shows the progress of synchronization
in percent.
Shows the secondary’s
readiness to take control.
Shows the secondary’s
readiness to take control.
Shows the state of the modules
(startup, faulted, etc).
Shows the state of the modules
(startup, faulted, etc).
Shows the compatibility between the primary and
secondary module.
Shows the compatibility between the primary and
secondary module.
• Shows the current state of all the modules in this redundant controller chassis.
Rockwell Automation Confidential
13
SRM Dialog Event Log Tab
• This dialog shows the history of the past 10 events.• Events that are logged include synchronizations, switchovers, etc.• This information is stored on the SRM module.
1757-SRM REDUNDANCY MODULE
Chassis_B: Primary with QualifiedSecondary
Rockwell Automation Confidential
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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.
You just select a single checkbox on the
controller properties dialog to enable
redundancy.
Rockwell Automation Confidential
15
Other Controller Properties Options
This enables
redundancy.
This enables
redundancy.
Lets you specify how much of the unused memory will be
allocated for adding data online versus adding program online.
Lets you specify how much of the unused memory will be
allocated for adding data online versus adding program online.
Allows you to specify whether you want test edits to remain in effect after a switchover.
This is useful for online edit changes.
Allows you to specify whether you want test edits to remain in effect after a switchover.
This is useful for online edit changes.
Here you can see the status of this controller chassis and this
controller.
Here you can see the status of this controller chassis and this
controller.
Here you can see the status of this controller’s redundant partner.
Here you can see the status of this controller’s redundant partner.
Rockwell Automation Confidential
16
Automatic cross-loading of programs
• You only have to download your program to the primary controller. The system will automatically cross-load the primary’s program to the secondary controller.
Allen-BradleyA-BQuality
ControlNET
CHA CHB OK
A#01
Redundancy Module
PRI COM OK
PRIM
RUN REM PROG
Logix5555™
RUN
OK
RS232
BAT
I/O
Allen-BradleyA-BQuality
ControlNET
CHA CHB OK
A#01
Redundancy Module
PRI COM OK
PRIM
RUN REM PROG
Logix5555™
RUN
OK
RS232
BAT
I/O
Rockwell Automation Confidential
17
Bumpless Switchovers
• The secondary controller is synchronized with the primary to provide a bumpless switchover for any outputs controlled by logic in the highest priority task:– Primary notifies secondary when user tasks start.
– Primary notifies secondary when programs complete & provide a complete data ‘snapshot’.
• Secondary doesn’t execute programs, but follows along, pending at each program start.
• Incomplete transfers are ‘quarantined’ on secondary until complete.
– At switchover, the new primary rolls back to the beginning of currently executing programs using ‘last good’ data snapshot.
Rockwell Automation Confidential
18
ControlLogix Redundant Power Supply1756-PA75R / -PB75RPower Supplies• 85 - 265 VAC and 19 - 32 VDC
Versions• Panel mount (1756-A4 footprint -
6.9" H x 5.7" W x 5.4" D)• Px75 equivalent capacity
1756-CPR Cables• 3 foot max length • Pin-outs provided if you want to
make shorter cables
1756-PSCAChassis Adapter Module• Passive device funnels power
to backplane• Series B chassis only
Failure Annunciation• Normally Open solid state relay on each supply• Wire to any input module