Allen-Bradley ControlLogix 5570 series Reference Manual
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Allen-Bradley ControlLogix 5570 series Reference Manual

Controllogix redundancy update and module replacement guidelines
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  • Page 1 Reference Manual Original Instructions ControlLogix Redundancy Update and Module Replacement Guidelines Product Family ControlLogix 5570 Controllers...
  • Page 2 Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

  • Page 3: Table Of Contents

    Table of Contents Preface ............5 Summary of Changes .
  • Page 4 Table of Contents Appendix A Align LINT Members on 8-byte ............. . 51 Boundaries Rockwell Automation Publication 1756-RM010C-EN-P - August 2018...

  • Page 5: Preface

    Preface Summary of Changes This table contains the changes that were made to this revision. Topic Page Added references to redundancy firmware revision 31.052 Throughout Added references to ControlFLASH Plus™ software Throughout Added section: Install the Revision 31.052 Redundancy Firmware Bundle Page 18 This publication provides instructions for replacing modules or updating Overview...

  • Page 6: Modernization Services And Tools

    Declarations of conformity, certificates, and other certification details. http://www.rockwellautomation.com/global/certification/overview.page You can view or download publications at http:/www.rockwellautomation.com/literature/. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative. Rockwell Automation Publication 1756-RM010C-EN-P - August 2018...

  • Page 7: Update Considerations

    Chapter Update Considerations Topic Page Before You Begin Download and Install ControlFLASH Software Download the Redundancy Firmware Bundle and RMCT Install the Redundancy Firmware Bundle Install the Redundancy Module Configuration Tool Install the Logix Designer Application Prepare the Controller Project for the Update Update the Redundancy System Firmware Before You Begin When updating products in a ControlLogix®...

  • Page 8: Lint Members Must Align On 8-Byte Boundaries

    Chapter 1 Update Considerations LINT Members Must Align on 8-byte Boundaries IMPORTANT If you have User-defined Data Types (UDT) that contain LINT members, you may not be able perform the online Redundancy System Update. See the ControlLogix Redundancy User Manual, publication 1756-UM535, on how to install and update the modules, firmware, and application software versions while offline.

  • Page 9: I/O Modules In Redundancy Systems

    Update Considerations Chapter 1 I/O Modules in Redundancy Systems In a redundancy system, you can use only I/O modules in a remote chassis. You cannot use I/O modules in the redundant chassis pair. This table describes the I/O modules that redundancy systems support. Remote I/O Module Placement Revision 20.054 and Later EtherNet/IP™...
  • Page 10 Chapter 1 Update Considerations 3. Right-click your redundancy module and choose Module Configuration. The Module Configuration dialog box opens. 4. Right-click the title bar and choose About. The About dialog box opens and indicates the RMCT version. TIP The RMCT launches at the version that is compatible with the 1756-RM2 or 1756-RM2XT redundancy module firmware that is installed.

  • Page 11: Download And Install Controlflash Software

    Update Considerations Chapter 1 Download and Install If you are upgrading to redundancy firmware revision 30.051 or 31.052, ControlFLASH software is not included in redundancy firmware revision kits. ControlFLASH Software You must download it separately. To update to redundancy firmware revision 30.051 or 31.052, you must use ControlFLASH version 15.01.00 or later, or ControlFlash Plus version 1.01.00 or later.
  • Page 12 Chapter 1 Update Considerations 3. Select the appropriate Enhanced Redundancy Bundle version. 4. Click Add to Download Cart. 5. Click Downloads. 6. On the Download Cart dialog, make sure that the firmware is selected, and click Download now. 7. You have to log in to download the redundancy firmware bundle. Follow the download instructions on the website.
  • Page 13 Update Considerations Chapter 1 The RMCT is included in the downloads for most redundancy bundles. For redundancy bundles that use firmware revision 20.009 or later for 1756-RM2 modules, the RMCT is included in the redundancy bundle and is not available for separate download.

  • Page 14: Install The Redundancy Firmware Bundle

    Chapter 1 Update Considerations Install the Redundancy This section details how to install the Redundancy Firmware Bundle. • If you are updating from revision 20.05x to revision 24.052, see Firmware Bundle Install the Revision 24.052 Redundancy Firmware Bundle on page •...
  • Page 15 Update Considerations Chapter 1 6. Clear Yes, I want to launch ControlFLASH. 7. Click Close. Rockwell Automation Publication 1756-RM010C-EN-P - August 2018...

  • Page 16: Install The Revision 30.051 Redundancy Firmware Bundle

    Chapter 1 Update Considerations Install the Revision 30.051 Redundancy Firmware Bundle If you are updating from revision 24.052 to revision 30.051, follow the steps in this section. TIP Create a 30.051 firmware directory on your computer first, so you can unzip the firmware files to this directory.
  • Page 17 Update Considerations Chapter 1 5. On the WinZip Self-Extractor dialog, click Browse and choose the location to install the files. 6. After you choose your location, click Unzip. 7. On the installation successful dialog, click OK 8. On the WinZip Self-Extractor dialog, click Close. Rockwell Automation Publication 1756-RM010C-EN-P - August 2018...

  • Page 18: Install The Revision 31.052 Redundancy Firmware Bundle

    Chapter 1 Update Considerations Install the Revision 31.052 Redundancy Firmware Bundle If you are updating from revision 30.051 to revision 31.052, follow the steps in this section. TIP Create a 31.052 firmware directory on your computer first, so you can unzip the files to this directory.

  • Page 19: Install The Redundancy Module Configuration Tool

    Update Considerations Chapter 1 Install the Redundancy If needed, install the latest version of the RMCT. Module Configuration Tool IMPORTANT If you have RMCT version 7 or earlier, it does not support the 1756-RM2 modules. For more information on the RMCT, see Knowledgebase article 29511.

  • Page 20: Install The Logix Designer Application

    Chapter 1 Update Considerations Install the Logix Designer This section describes how to install the Logix Designer that is compatible with your redundancy firmware bundle. Application IMPORTANT If you update your programming software from version 20 to version 24, we strongly recommend that you read Rockwell Automation Knowledgebase Answer ID 565204 - RSLogix 5000®...

  • Page 21: Prepare The Controller Project For The Update

    Update Considerations Chapter 1 Prepare the Controller To prepare the controller project and controllers for the update, complete these steps. Project for the Update 1. Start the Logix Designer application, and select your redundancy project. 2. Go online with the primary controller. 3.
  • Page 22 Chapter 1 Update Considerations 14. Click OK. The Logix Designer application converts the project to the latest revision. 15. Access the Module Properties for each communication module in the chassis and specify the module firmware revision that you are upgrading TIP If you are unable to specify the new revision, you must change the Electronic Keying parameter to Compatible Module.

  • Page 23: Update The Redundancy System Firmware

    Update Considerations Chapter 1 Update the Redundancy You can update redundancy firmware to another revision while your process continues to run. This update is known as Redundancy System Update (RSU). System Firmware IMPORTANT Remember the following before using this section: •...

  • Page 24: Prepare The Redundant Chassis For The Firmware Update

    Chapter 1 Update Considerations Complete the steps in this table to update your redundancy system from one redundancy system revision to another redundancy revision while your process continues to run. Task Page Prepare the Redundant Chassis for the Firmware Update Update the Redundancy Module Firmware in the Primary Chassis Update Redundancy Module Firmware and Other Module Firmware in the Secondary Chassis 28 Lock the System and Initiate a Switchover to Update...

  • Page 25: Update The Redundancy Module Firmware In The

    Update Considerations Chapter 1 5. From the Auto-Synchronization pull-down menu, choose Never. 6. Click Apply, and then click Yes. 7. Click the Synchronization tab. 8. Click Disqualify Secondary. 9. On the RMCT Confirmation dialog, click Yes. The secondary chassis is disqualified as indicated by the RMCT at the bottom-left of the RMCT and on the status display of the redundancy module.

  • Page 26: Primary Chassis

    Chapter 1 Update Considerations Update the Redundancy Module Firmware in the Primary Chassis IMPORTANT If your system has 1756-RM or 1756-RMXT modules, you must replace them with 1756-RM2 or 1756-RM2XT modules. See Replace a 1756-RM Module with a 1756-RM2 Module on page 49 for more information.
  • Page 27 Update Considerations Chapter 1 b. On the Browse for Folder dialog, select the location of your firmware files. c. Click OK. 4. On the ControlFlash dialog, select the redundancy module catalog number as the target device. 5. Click Next 6. Browse to the redundancy module in the primary chassis and select it. Primary Chassis Secondary Chassis 7.

  • Page 28: Update Redundancy Module Firmware And Other Module Firmware In The Secondary Chassis

    Chapter 1 Update Considerations Update Redundancy Module Firmware and Other Module Firmware in the Secondary Chassis Make sure that the secondary chassis is powered on. If you have to power on the chassis, wait at least 45 seconds before you begin the secondary update. During this time, the redundancy module conducts internal operations to prepare for an update.
  • Page 29 Update Considerations Chapter 1 6. Select the firmware revision to update to and click Next. 7. Click Finish. The firmware begins to update. When the update is complete, the Update status dialog box indicates completion. 8. On the Update status dialog, click OK. 9.

  • Page 30: Lock The System And Initiate A Switchover To Update

    Chapter 1 Update Considerations Lock the System and Initiate a Switchover to Update Once you have downloaded the controller project, complete these steps to lock your system and initiate a switchover. IMPORTANT Remain offline while completing these steps. • Once you have locked the system, do not abort the system lock. Aborting the system lock during this procedure clears the project from the secondary controller.
  • Page 31 Update Considerations Chapter 1 The System Update Lock Attempts log indicates when the system lock is complete. 5. Click Initiate Locked Switchover, and then click Yes at the Redundancy Configuration Tool dialog box. Your secondary chassis assumes control and becomes the primary chassis.

  • Page 32: Update The New Secondary Chassis Firmware

    Chapter 1 Update Considerations Update the New Secondary Chassis Firmware IMPORTANT Update the Gateway address of the primary chassis Ethernet module to 192.168.1.1, if you are upgrading from a system using revision 20.054_kit1, 20.055_kit1, 20.055_kit2, 20.055_kit3, 20.055_kit4, or 20.056_kit1 and Electronic Keying is set to Exact Match, Compatible Module or Disable Keying and you are either: a.
  • Page 33 Update Considerations Chapter 1 4. Browse to the module and select it. Primary Chassis Secondary Chassis 5. Click OK. 6. Select the firmware revision to update to and click Next. 7. Click Finish. The firmware begins to update. When the update is complete, the Update status dialog box indicates completion.

  • Page 34: Synchronize The Redundant Chassis

    Chapter 1 Update Considerations Synchronize the Redundant Chassis To synchronize the redundant chassis after firmware in both chassis have been updated to the same revision, complete these steps. 1. In RSLinx software, right-click the 1756-RM2 or 1756-RM2XT module in the primary chassis and choose Module Configuration to open the RMCT.

  • Page 35: Eds Files

    Update Considerations Chapter 1 6. Repeat this process for all Ethernet modules that need the rotary switches set back to 2…254. 7. From the Auto-Synchronization pull-down menu, choose the frequency that suits your application. 8. If necessary, manually synchronize the chassis. 9.
  • Page 36 Chapter 1 Update Considerations Notes: Rockwell Automation Publication 1756-RM010C-EN-P - August 2018...

  • Page 37: Replacement Considerations

    Chapter Replacement Considerations Topic Page Before You Begin Replace a Module in the Secondary Chassis That Has the Same Catalog Number and Firmware Revision Replace an EtherNet/IP Module with a New Series Replace a 1756-CN2 Module with a New Series Replace a 1756-RM Module with a 1756-RM2 Module Before You Begin When replacing modules in ControlLogix®...

  • Page 38: Replace A Module In The Secondary Chassis That Has The Same Catalog Number And Firmware Revision

    Chapter 2 Replacement Considerations Replace a Module in the These steps are used when performing a direct communication module replacement, for example, when replacing a communication module in the Secondary Chassis That Has the secondary chassis with a module that has the same: Same Catalog Number and •...

  • Page 39: Replace An Ethernet/Ip Module With A New Series

    Replacement Considerations Chapter 2 Replace an EtherNet/IP Module This section describes how to replace EtherNet/IP communication modules in a redundancy system without the need for a controller update. with a New Series You can replace the EtherNet/IP modules by using the following methods: •...
  • Page 40 Chapter 2 Replacement Considerations 5. For each module, verify that the Electronic Keying is set to Compatible Module or Disable Keying. 6. In the RSLinx® Classic software, start the RMCT for the redundancy module in either chassis. 7. On the Configuration tab, from the Auto-Synchronization pull-down menu, choose Never.
  • Page 41 Replacement Considerations Chapter 2 10. Make a note of the Port Configuration of the secondary Ethernet module. • IP address • Network Mask • Gateway address 11. Disconnect the Ethernet cables from the secondary Ethernet module. 12. Turn off power to the secondary chassis. 13.
  • Page 42 Chapter 2 Replacement Considerations b. Select the Ethernet module catalog number and click Next. c. Browse to the module in the secondary chassis and select it. Secondary Chassis d. Click OK. e. Select the firmware revision to update to and click Next. f.
  • Page 43 Replacement Considerations Chapter 2 2. On the Synchronization tab, synchronize the secondary chassis. Wait for synchronization to complete. 3. Initiate a switchover. 4. Disconnect the Ethernet cables from the secondary Ethernet module. 5. Turn off power to the secondary chassis. 6.

  • Page 44: Replace A 1756-Cn2 Module With A New Series

    Chapter 2 Replacement Considerations Replace a 1756-CN2 Module with This section describes how to replace ControlNet communication modules in a redundancy system. You can replace the 1756-CN2/B modules with a New Series 1756-CN2/C modules by using the following methods: • Synchronization and Switchover for the ControlNet Modules Use this method if Electronic Keying is set to Disable or Compatible Module.
  • Page 45 Replacement Considerations Chapter 2 4. For the 1756-RM2 and 1756-RM2XT modules: • With redundancy firmware revision 24.052, make sure that the redundancy module firmware is revision 20.007 or later. • With redundancy firmware revision 30.051, make sure that the redundancy module firmware is revision 20.009 or later. •...
  • Page 46 Chapter 2 Replacement Considerations 10. On the Synchronization tab, click Disqualify Secondary and then click Yes. 11. Disconnect the coaxial cables from the secondary ControlNet module. 12. Remove the original ControlNet module from the secondary chassis. 13. Set the switches in the new module to 00 and insert the module into the secondary chassis.
  • Page 47 Replacement Considerations Chapter 2 The firmware begins to update. When the update is complete, the Update status dialog box indicates completion. Wait for the update to complete. 18. Wait for communication to resume on the network. 19. Verify that the Synchronization Status tab indicates that the modules are fully compatible.
  • Page 48 Chapter 2 Replacement Considerations Complete these steps to verify module compatibility and synchronization. 1. In the RMCT, from the Auto-Synchronization pull-down menu, choose your preferred method. 2. If necessary, manually synchronize the chassis. 3. Click Apply, Yes, and OK. 4. Verify that the secondary chassis has qualified. Rockwell Automation Publication 1756-RM010C-EN-P - August 2018...

  • Page 49: Replace A 1756-Rm Module With A 1756-Rm2 Module

    Replacement Considerations Chapter 2 Replace a 1756-RM Module with You can replace 1756-RM modules with 1756-RM2 modules without initiating a switchover. a 1756-RM2 Module 1. Install the compatible version of the RMCT software. You must shut down RSLinx Classic software to install the software, and then restart RSLinx Classic software after the installation is complete.
  • Page 50 Chapter 2 Replacement Considerations Notes: Rockwell Automation Publication 1756-RM010C-EN-P - August 2018...

  • Page 51: Align Lint Members On 8-Byte

    Appendix Align LINT Members on 8-byte Boundaries The Studio 5000 Logix Designer® application has requirements for data type use. The requirements differ based on the Logix Designer application version that you use. Logix Designer Application Version Requirement Version 26 or earlier Logix 5000™...
  • Page 52 Appendix A Align LINT Members on 8-byte Boundaries To correct Produce/Consume errors that are caused by UDT alignment changes, modify the tag structures in both projects so that they match. • Produce/Consume with Status requires an exact match of the UDT definition (including the name of the UDT definition).
  • Page 53 Align LINT Members on 8-byte Boundaries Appendix A Table 1 illustrates how this data structure maps in a Logix Designer project, version 24.052 or earlier. MyLint is split across two 64-bit words, and the total size is only 32 bytes. Table 1 - Data Structure for Logix Designer Projects, Version 26 or Earlier Word Elements...
  • Page 54 Appendix A Align LINT Members on 8-byte Boundaries To create a UDT that is the same size in all types of projects, insert additional data elements so that hidden padding bytes are not necessary. The following sample UDT illustrates how UnusedDint1 and UnusedDint2 were added to create a UDT with the same size in a Logix Designer project, version 24.052 or earlier compared to a Logix Designer project, version 30.051 or later.
  • Page 55 Align LINT Members on 8-byte Boundaries Appendix A To correct any mismatched UDTs, complete the following tasks in either project: 1. Start at the deepest nesting level of any multi-level UDT. 2. Work from the beginning of each structure and look for LINT data types.
  • Page 56 Appendix A Align LINT Members on 8-byte Boundaries Notes: Rockwell Automation Publication 1756-RM010C-EN-P - August 2018...
  • Page 58 Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, ControlFLASH, ControlFLASH Plus, ControlLogix, Data Highway Plus, FactoryTalk, Integrated Architecture, Logix5000, Rockwell Automation, Rockwell Software, RSLinx, RSLogix 5000, RSNetWorx, and Studio 5000 Logix Designer are trademarks of Rockwell Automation, Inc.

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