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TROUBLESHOOTING

CHAPTER8 TROUBLESHOOTING

This chapter provides troubleshooting methods of redundant system.

Error codes, special relays, and special registers of redundant CPU are not covered in this
manual. Refer to the following manual, for error codes, special relays, and special
registers of redundant CPU.

QCPU User's Manual (Hardware Design, Maintenance and Inspection)

The CPU module status can be confirmed by the LEDs, which are situated on the front
face of the CPU module. The CPU module LEDs necessary for troubleshooting of
redundant system are explained here.

Diagram 8.1 CPU Module LEDs

Table8.1 LED Names and Explanations

No.

Name

Explanation

1)

MODE LED

Indicates the CPU module mode.
On (Green)

: Q Mode.

Flashing (Green) : External I/O Forced ON/OFF has been registered.

2)

RUN LED

Indicates the CPU module operation status.
On

: The CPU is Running. The RUN/STOP switch: RUN position.

Off

: The CPU has Stopped. The RUN/STOP switch: STOP position.

The standby system CPU module in backup mode.
(The RUN/STOP switch: RUN position.)
An error that stops operation has been detected.

Flashing : The RUN/STOP switch is set to the STOP position to write parameters/

programs into CPU, and then the switch is returned from the STOP to
RUN position.The standby system CPU module for which the operation
mode is switched from backup mode to separate mode.

3)

ERR.LED

On

: The self diagnostics error that does not stop the operation (other than

battery error) is detected.
(The settings have been made by the parameter so that the operation is
continued when an error is detected.)

Off

: Normal.

Flashing : An error that stops operations has been detected.

Automatic write to the standard ROM is completed (BOOT LED is also
flashing.)

Q12PRHCPU

MODE

RUN

ERR.

USER

BAT.

BOOT

BACKUP

SYSTEM B

SYSTEM A

CONTROL

7)

2)

3)

4)

5)

6)

1)

8)

9)

10)

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Summary of Contents for Q12PRHCPU

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Page 3: ...n or upper lower limit positioning 2 The programmable controller stops its operation upon detection of the following status and the output status of the system will be as shown below All outputs may turn on when an error occurs in the part such as I O control part where the CPU module cannot detect any error To ensure safety operation in such a case provide a safety mechanism or a fail safe circui...

Page 4: ...vant manuals carefully and ensure the safety before operation Especially in the case of a control from an external device to a remote programmable controller immediate action cannot be taken for a problem on the programmable controller due to a communication failure To prevent this configure an interlock circuit in the sequence program and determine corrective actions to be taken between the exter...

Page 5: ...sion cable connect it to the extension cable connector of the base unit securely Check the connection for looseness Poor contact may cause incorrect input or output When using a memory card fully insert it into the memory card slot Check that it is inserted completely Poor contact may cause malfunction Shut off the external power supply for the system in all phases before mounting or removing the ...

Page 6: ...sconnected when the terminal screw comes loose resulting in failure Check the rated voltage and terminal layout before wiring to the module and connect the cables correctly Connecting a power supply with a different voltage rating or incorrect wiring may cause a fire or failure Connectors for external connection must be crimped or pressed with the tool specified by the manufacturer or must be corr...

Page 7: ...tion against electric shock For wiring methods refer to the QCPU User s Manual Hardware Design Maintenance and Inspection WARNING Do not touch any terminal while power is on Doing so will cause electric shock Correctly connect the battery connector Do not charge disassemble heat short circuit solder or throw the battery into the fire Doing so will cause the battery to produce heat explode or ignit...

Page 8: ...e to fail or malfunction A module can be replaced online while power is on on any MELSECNET H remote I O station or in the system where Redundant CPUs are used Note that there are restrictions on the modules that can be replaced online and each module has its predetermined replacement procedure For details refer to Section 2 4 After the first use of the product do not mount remove the module to fr...

Page 9: ...her wastes according to the local regulations For details of the Battery Directive in EU member states refer to the QCPU User s Manual Hardware Design Maintenance and Inspection CAUTION When transporting lithium batteries follow the transportation regulations For details of the regulated models refer to the QCPU User s Manual Hardware Design Maintenance and Inspection ...

Page 10: ...se of the PRODUCT in Nuclear Power Plants and any other power plants operated by Power companies and or any other cases in which the public could be affected if any problem or fault occurs in the PRODUCT Railway companies or Public service purposes and or any other cases in which establishment of a special quality assurance system is required by the Purchaser or End User Aircraft or Aerospace Medi...

Page 11: ...g Redundant CPU serial No 09012 Q65WRB SAFETY PRECAUTIONS Section 1 1 1 2 2 1 2 3 2 4 Chapter 4 Section 4 1 4 2 4 4 5 1 3 5 1 4 5 1 5 5 3 1 5 2 5 4 5 5 1 5 6 1 5 8 5 10 1 5 10 2 6 1 3 6 2 6 2 1 6 2 2 6 2 3 6 2 4 6 2 5 6 3 6 3 1 6 3 2 6 3 3 6 3 4 7 1 7 2 Chapter 8 Section 8 1 2 8 1 4 8 1 5 8 3 4 8 3 6 9 2 Appendix 1 Appendix 2 Appendix 3 Section 8 1 9 8 1 10 8 1 11 8 3 8 8 3 10 Chapter 6 Section 6 ...

Page 12: ...3 2 8 3 3 8 3 4 8 3 5 8 3 6 8 3 9 9 2 Appendix 1 Appendix 2 Appendix 3 Appendix 4 1 Appendix 5 Section 8 1 12 8 1 13 8 1 14 8 1 15 Mar 2009 SH NA 080486ENG L Section 2 4 7 1 Jul 2009 SH NA 080486ENG M SAFETY PRECAUTIONS GENERIC TERMS AND ABBREVIATIONS Apr 2010 SH NA 080486ENG N SAFETY PRECAUTIONS Section 2 3 5 5 1 6 3 Appendix 4 4 CONDITIONS OF USE FOR THE PRODUCT Jun 2011 SH NA 080486ENG O INTROD...

Page 13: ...es 3 1 3 3 Connecting and Disconnecting a Tracking Cable 3 2 CHAPTER4 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM 4 1 to 4 17 4 1 Mounting Modules 4 6 4 2 Wiring 4 7 4 3 Module Initial Settings 4 12 4 4 Confirming that the Power Supply is ON 4 12 4 5 Confirming System A System B 4 13 INTRODUCTION Thank you for choosing the Mitsubishi MELSEC Q Series of General Purpose Programmable Controllers Bef...

Page 14: ...tem Switching 5 51 5 3 5 Special Relays Registers For System Switching 5 53 5 3 6 System Switching Precautions 5 56 5 4 Operation Mode Change Function 5 58 5 5 Tracking Function 5 73 5 5 1 Tracking Function Overview 5 73 5 5 2 Tracking Execution Procedure 5 76 5 5 3 Tracking Data 5 77 5 5 4 Tracking Data Settings 5 82 5 5 5 Tracking Block And Tracking Trigger 5 84 5 5 6 Tracking Execution 5 88 5 5...

Page 15: ...ther Station 6 54 CHAPTER7 PROGRAMMING CAUTIONS 7 1 to 7 23 7 1 Instructions Restricted in Use for Redundant System 7 1 7 2 Cautions on Fixed Scan Clocks and Fixed Scan Execution Type Programs 7 9 7 3 Precautions for Using Annunciator F in Redundant System 7 14 7 4 Precautions at System Switching Occurrence 7 17 7 5 Precautions of Programming when Connecting Extension Base Unit 7 23 CHAPTER8 TROUB...

Page 16: ... to Tracking 9 2 9 2 System Switching Time 9 6 APPENDICES App 1 to App 56 Appendix 1 Comparison of Q4ARCPU and QnPRHCPU App 1 Appendix 2 Comparison of Qn H CPU and QnPRHCPU App 5 Appendix 3 Comparison of QnPHCPU and QnPRHCPU App 9 Appendix 4 Sample Programs when Using CC Link App 13 Appendix 4 1 Sample Program System Configuration App 13 Appendix 4 2 Sample Program Names App 13 Appendix 4 3 Device...

Page 17: ...parately SH 080041 13JF60 MELSEC Q L Programming Manual MELSAP L This manual describes the programming methods specifications functions and so on that are necessary to create the MELSAP L type SFC program Sold separately SH 080076 13JF61 QnPHCPU QnPRHCPU Programming Manual Process Control Instructions This manual describes the programming procedures device names and other items necessary to implem...

Page 18: ...and the troubleshooting Sold separately SH 080009 13JL88 Q Corresponding Ethernet Interface Module User s Manual Application This manual explains the e mail function of the Ethernet module the programmable controller CPU status monitoring function the communication function via MELSECNET H MELSECNET 10 as well as the communication function using data link instructions and how to use file transfer ...

Page 19: ...or these functions refer to the manual shown below Qn H QnPH QnPRHCPU User s Manual Function Explanation Program Fundamentals 1 Chapter 1 and 2 Explains the redundant system overview and system configuration 2 Chapter 3 Explains the tracking cable specifications part names and connection method 3 Chapter 4 Explains starting up the redundant system 4 Chapter 5 Explains the redundant system function...

Page 20: ...pter heading The index on the right side of the page shows the chapter of the open page at a glance Section title The section of the open page is shown at a glance Reference destination A reference destination or reference manual is marked ...

Page 21: ...lowing explanations POINT Explains the matters to be especially noted the functions and others related to the description on that page Remark Provides the reference destination related to the description on that page and the convenient information ...

Page 22: ...subishi MELSEC Q Series Programmable Controller GX Developer Product name for SW D5C GPPW E GPP function software package compatible with the Q series indicates the version OPS Abbreviation for the operation system that includes MELSOFT and EZSocket partner products CC Link IE Controller Network module Abbreviation for the QJ71GP21 SX and QJ71GP21S SX CC Link IE Controller Network module MELSECNET...

Page 23: ...0TR and QC30TR tracking cables for Redundant CPU Q series power supply module Generic term for the Q61P A1 Q61P A2 Q61P Q61P D Q62P Q63P Q64P and Q64PN power supply modules Slim type power supply module Abbreviation for the Q61SP slim type power supply module Redundant power supply module Generic term for the Q63RP and Q64RP redundant power supply module Power supply module Generic term for the Q ...

Page 24: ...is the other system Control system The basic system that is controlling the redundant system and performing network communication Standby system The basic system for backup that consists of the redundant system New control system The system that has switched to control system from standby system after system switching New standby system The system that has switched to standby system from control s...

Page 25: ... redundant system configuration that includes redundant CPUs and relevant functions etc Please refer to the following manuals for common specifications performance functions and others to QCPUs 1 Specifications and handling of QCPUs Power Supply Modules Base Units memory Cards etc QCPU User s Manual Hardware Design Maintenance and Inspection 2 Common Functions Programs and Devices for QCPUs QCPU U...

Page 26: ...ndant System Confirmation of part names and specifications of the CPU module Confirmation of connection methods for power supply module base unit and I O module Construction of redundant system confirmation of start up procedure and I O number assignment Confirmation of the configuration and memory of sequence programs Confirmation of the functions parameters devices etc of the CPU module Confirma...

Page 27: ...ELSAP L QCPU Q mode Programming Manual Structured Text Edition Confirmation of usage of sequence instructions basic instructions application instructions etc Confirmation of dedicated instructions for PID control Confirmation of dedicated instructions for process control Confirmation of MELSAP3 s system configuration performance specifications functions programming debugging and error codes Confir...

Page 28: ...ed Then connect the CPU modules of both systems with a tracking cable I O module s and intelligent function module s are installed to MELSECNET H remote I O station s or extension base unit s in redundant systems Power supply redundancy is also available by using redundant power main base units or redundant power extension base units Diagram 1 1 Configuration Example of Redundant System MELSECNET ...

Page 29: ... error occurs in the control system the standby system takes over the control of the redundant system 3 Refer to Section 2 3 for details of network modules compatible for redundant system Remark The redundant system described in this manual does not guarantee continuous operation of the system depending on the failure status Also when system switching occurs due to an extension base unit error or ...

Page 30: ...undant system control after the control system goes down and system switching occurs 1 The control system indicates the system that actually controls the a redundant system Section 5 1 2 2 The standby system indicates the backup system within a redundant system Section 5 1 2 If an error occurs in the control system the standby system takes over the control of the redundant system 3 Refer to Sectio...

Page 31: ...5 digits of serial No is 09012 or later is used in both systems the extension base unit can be connected 1 Since communication can be made not by network but via bus communication with the I O module and the intelligent function module can be made in high speed 1 For the precautions of the system configuration when connecting the extension base unit refer to Section 2 4 Diagram 1 3 System Configur...

Page 32: ...work interface board refer to the following manual CC Link IE Controller Network Interface Board User s Manual Diagram 1 4 System Configuration for CC Link IE Controller Network CC Link IE Controller Network CC Link IE Controller Network Control system Normal station Standby system Standby system Normal station Tracking cable Tracking cable OPS Normal station CC Link IE Controller Network interfac...

Page 33: ...hen control standby system switching occurs Section 6 2 2 Diagram 1 5 System Configuration for MELSECNET H Remote I O Network MELSECNET H Remote I O network Control system Standby system Tracking cable Tracking cable Remote I O station Multiplexed Remote Master Station Multiplexed Remote Sub master Station Remote I O station Remote I O station MELSECNET H Remote I O network Control system Remote I...

Page 34: ... Redundant system settings such as tracking settings network pairing settings etc can be made easily in the parameter settings of GX Developer Diagram 1 6 System Configuration for PROFIBUS DP An error has been detected Tracking cable Control system DP Slave DP Slave Standby system Bus terminator Bus terminator Tracking cable New standby system DP Slave DP Slave New control system Control system St...

Page 35: ... and standby system without the need to identify each system Parameters and programs can be written into both of control system and standby system using GX Developer There is no need to identify each system Section 5 6 1 Diagram 1 7 Writing to the Control System and Standby System by Download to PLC Control system Standby system Tracking cable 1 to 3 denotes the process up to writing 1 2 3 Execute...

Page 36: ...executing the transfer command from GX Developer This operation can also be done via special relays and special registers Section 5 7 Diagram 1 8 Copy of Parameters and Programs when CPU Module is Replaced Control system Standby system Tracking cable 1 Replacing the CPU module 2 Transfer 3 Send parameters programs 1 to 3 shows the procedure to copy parameters and programs to the replaced CPU modul...

Page 37: ...n in advance 8 Compatible with Q series modules Q series modules such as the I O module intelligent function module and network module can be applied to a redundant system without making any modifications Some models are irrelevant Section 2 3 Therefore equipments within factories can be utilized maintenance costs can be reduced and the system can be expanded Diagram 1 9 System Configuration for E...

Page 38: ...te that a module mounted to the main base unit cannot be replaced online when the extension base unit is connected Diagram 1 10 Online Module Change Hot Swapping of Remote I O Stations MELSECNET H Remote I O network Remote I O station Remote I O station Control system Standby system Tracking cable Failed module Replacement module Set online module change hot swapping Online module change hot swapp...

Page 39: ...m can be monitored using the System Monitor of GX Developer Diagram 1 11 Online Module Change Hot Swapping of I O Modules mounted on a Main Base Unit Diagram 1 12 System Monitor of GX Developer Control system Standby system Tracking cable 2 Online module change hot swapping Replacement module Set online module change hot swapping 1 Cancel online module change hot swapping 1 to 3 shows the online m...

Page 40: ...e applicable 12 Flexible layout The layout can be changed flexibly because the main base unit is divided into two units for the control system and standby system Diagram 1 13 Horizontal Arrangement of Control System and Standby System Diagram 1 14 Vertical Arrangement of Control System and Standby System Tracking cable Control system Standby system Tracking cable Control system Standby system ...

Page 41: ...dules compatible with the redundant system refer to Section 2 3 and Section 2 4 Diagram 2 1 Example of Redundant System Configuration MELSECNET H MELSECNET 10 Mode PLC to PLC network communication with other stations CC Link I O control communication with external systems Ethernet communication with upper layer QCPU Normal station CC Link IE Controller Network communication with other stations 2 Q...

Page 42: ...l system If one of the systems is started up before the other the system started up first becomes the control system 1 Section 5 1 2 POINT The extension base unit cannot be connected to the main base unit where the Redundant CPU whose first 5 digits of serial No is 09011 or earlier is mounted If connected a stop error BASE LAY ERROR error code 2010 occurs When connecting the extension base unit us...

Page 43: ...placed for preventive maintenance while the system is running c Module which can be mounted to main base unit or extension base unit For the module which can be mounted to the main base unit or extension base unit refer to Section 2 3 d Redundant System Operations Refer to Section 5 1 for redundant system operations POINT The extension base unit cannot be connected to the main base unit where the ...

Page 44: ...g System Switching Refer to Section 6 2 3 for an overview of communication methods between the OPS and PC connected to Ethernet and CPU modules of a redundant system and operations during system switching Refer to the Q Corresponding Ethernet Interface Module User s Manual Basic for details Diagram 2 4 Connection of Redundant System to Ethernet OPS Personal computer Ethernet System A Control Syste...

Page 45: ...iring Settings and Relevant CPU Modules Pairing settings must be made using the control station network parameters when connecting a redundant system to CC Link IE Controller Network MELSECNET H or MELSECNET 10 The following CPU modules include the network parameters for paring settings Redundant CPU 1 High Performance model QCPU 1 Process CPU 1 Basic model QCPU 1 Universal model QCPU 1 Q4ARCPUs 1...

Page 46: ...nput module Input module Output module MELSECNET H MELSECNET 10 Mode PLC to PLC network communication with other stations System A Control System System B Standby System System A Control System Tracking cable Normal station Control station Normal station Normal station Normal station Normal station Power supply module Power supply module Power supply module Power supply module Power supply module ...

Page 47: ...are also available by installing a communication module to a remote I O station when it cannot be mounted on the main base unit of the redundant system b Backup of Power Supply Module The power supply module for each remote I O station can be backed up By adding a backup power supply module to a remote I O station the remote I O station can continue to operate even if an error occurs in either pow...

Page 48: ... Power supply module Power supply module Power supply module Output module Output module Output module Output module Input module Input module Input module Input module Input module Input module Input module Input module Input module Input module Input module Output module Output module Intelli Intelli Input module Input module Input module Input module Output module Output module MELSECNET H Remo...

Page 49: ... CC Link master module setting Set the CC Link master modules as follows 1 When mounting to the main base unit System A master station System B standby master station If A system is standby master station and B system is master station data link cannot be made Also start the system so that A system can be the control system Section 5 1 2 If B system starts as the control system CC Link communicati...

Page 50: ...e system so that system A will be the control system If starting up the system B as the control system CC Link cannot make communication since the master station of the CC Link does not exist Diagram 2 7 Connection of Redundant System to CC Link System A Control System System B Standby System Power supply module Power supply module Tracking cable Remote I O station CC Link Remote device station Lo...

Page 51: ...BUS DP For the method of communications with slave stations connected to the PROFIBUS DP and operation overview at system switching refer to Section 6 2 6 For the method of communications with slave stations connected to the PROFIBUS DP and operation details at system switching refer to the following manual PROFIBUS DP Master Module User s Manual Diagram 2 8 Connection of Redundant System to PROFI...

Page 52: ... 2 Refer to the following manual for details on writing to memory card and USB cable GX Developer Version 8 Operating Manual 3 Refer to Section 2 3 for versions of GX Developer PX Developer and GX Simulator applicable to redundant CPU Diagram 2 9 Peripheral Device Configuration Personal Computer GX Developer PX Developer GX Simulator 2 3 Memory Card 1 Redundant CPU RS 232 Cable USB Cable 2 Memory ...

Page 53: ...e Q38RB is used 3 indicates the type of the input module or output module 4 The QJ61BT11 cannot be mounted on a main base unit where a redundant CPU is mounted 5 For checking of the serial No and function version refer to 2 in this section 6 For restrictions on the number of modules that can be mounted to a main base unit in a redundant CPU system refer to Section 2 4 7 Mountable to extension base...

Page 54: ... O Network c Modules that cannot be mounted to extension base units The following modules cannot be mounted to extension base units CC Link IE Controller Network module MELSECNET H module Ethernet module function version B or earlier Web server module first 5 digits of serial No 09011 or earlier MES interface module first 5 digits of serial No 09011 or earlier Interrupt module PROFIBUS DP master m...

Page 55: ...l No and function version of the CPU module can be confirmed on the rated plate b Checking on the front of the module The serial number written on the rating plate is displayed on the front at the bottom of the module Remark The serial number is displayed on the front of the module from March 2008 production Products manufactured during switching period may not have the serial number on the front ...

Page 56: ...tion module can also be confirmed POINT The serial number displayed on the Product information list screen of GX Developer may differ from that on the rating plate and on the front of the module The serial No on the rated plate describes the management information of the product The serial No displayed on the product information of GX Developer describes the function information of the product The...

Page 57: ... version 1 16S or later when mounting CC Link master module on extension base unit Table2 2 Available GX Developer and PX Developer versions Product Name Model Version GX Developer SW8D5C GPPW E Ver 8 17T or later 1 3 PX Developer SW1D5C FBDQ E Ver 1 05F or later 2 4 GX Simulator SW6D5C LLT E Ver 6 20W or later Table2 3 Available GX Configurator versions Product Name Model Version GX Configurator ...

Page 58: ... multiple CPU system is not allowed Do not power OFF or reset the control system in Separate mode Do not perform boot operation of a Redundant CPU whose first 5 digits of serial No is 09011 or earlier using a memory card storing network parameters for Ethernet and CC Link configurations on an extension base unit Do not disconnect the extension cable while the power supply module mounted on the mai...

Page 59: ...ting Manual Programming Tool POINT Only the control system can access modules on the extension base units If accessing the standby system while the system monitor function of GX Developer is in execution the extension base units and modules on them are not displayed Using GX Developer with specifying Control system at Target system in the Transfer Setup screen is preferable 2 Modules that can be m...

Page 60: ...of serial number for the Redundant CPUs in both systems are 09102 or higher and GX Developer version is 8 58L or later In other combinations the number of mountable modules per system is 4 POINT If setting 5 or more at No of boards in module in CC Link network parameter of GX Developer version 8 55H or earlier the following error dialog box appears In this case set 4 or less at No of boards in mod...

Page 61: ...as a system In some cases they may start up as a system even when configured differently Refer to Section 5 1 4 for details 5 Number of Slots Occupied by a Redundant CPU A redundant CPU occupies two slots Main base unit slot 0 is set as follows type redundant points 0 points The I O number for slot 1 in which modules are mounted is X Y0H Diagram 2 13 Number of Slots Occupied by Redundant CPU and I...

Page 62: ...is mounted QCPU User s Manual Hardware Design Maintenance and Inspection b Extension base unit Q Corresponding MELSECNET H Network System Reference Manual Remote I O network Refer to the manual of each module for online module change hot swapping of analog input module analog output module temperature adjustment module and pulse input module 7 Cables applicable to coaxial bus system of MELSECNET H...

Page 63: ...cable to from the CPU module 3 1 Specifications The tracking cable specifications are shown in Table3 1 3 2 Part Names Tracking cable part names are indicated here P Table3 1 Tracking Cable Specifications Item Name QC10TR QC30TR Cable Length 1 0 m 3 29 feet 3 0 m 9 87 feet Purpose Connecting the CPU modules of a redundant system Mass 0 15 kg 0 28 kg Tightening Torque 29 4N cm No Name 1 System A Co...

Page 64: ...s less than 27 6 mm a malfunction may occur due characteristic deterioration wire breakage etc POINT 1 Always power OFF the standby system or set the RESET L CLR switch of the standby system CPU module to RESET before connecting or disconnecting the tracking cable 2 To connect or disconnect the tracking cable hold it by the cable connector Diagram 3 1 Minimum Bending Radius of a Tracking Cable Tra...

Page 65: ...Section 5 1 1 for confirming System A and System B b Hold the tracking cable connector and align it with the CPU module TRACKING connector c Connect the tracking cable connector to the CPU module TRACKING connector d Tighten the connector fixing screws and fix the connector to the CPU module Diagram 3 2 Checking the Connection Orientation of the Tracking Connector Diagram 3 3 Connecting the Tracki...

Page 66: ...ector fixing screws b When disconnecting the tracking cable hold the tracking cable connector and then remove it Diagram 3 5 How to Loosen the Connector Fixing Screws Diagram 3 6 Disconnecting the Tracking Cable Connector screws Flathead screwdriver Tracking cable Redundant CPU Connector TRACKING connector Tracking cable ...

Page 67: ...cting the extension base unit connect the main base unit and the extension base unit by an extension cable 5 Connect the network wiring to the network module 1 6 Connect the I O module Module Initial Settings Refer to Section 4 3 1 Set the RUN STOP switch of the CPU module to the STOP position 2 Set the RESET L CLR switch of each CPU module to the reset switch neutral position 3 Make switch settin...

Page 68: ...le 2 Simultaneously power on system A and system B or simultaneously set the RESET L CLR switches of both CPU modules to reset switch neutral position Error Check Refer to Section 4 9 Check if the ERR LEDs of system A and system B CPU modules are OFF If the ERR LEDs are ON flashing check the error cause using the System Monitor or diagnostics 4 of GX Developer and eliminate it Checking the Control...

Page 69: ...ncludes PLC diagnostics Ethernet diagnostics CC IE Control diagnostics MELSECNET diagnostics and CC Link CC Link LT diagnostics For details refer to each network manual 5 If the RUN STOP switch of standby CPU module is set to RUN and the operation status differs between the control system and standby system the consistency check causes OPE MODE DIFF error code 6010 in the control system CPU module...

Page 70: ... CPU module to the STOP position 2 Set the RESET L CLR switch of the CPU module to the reset switch neutral position 3 Make switch settings for the MELSECNET H module Checking that Power Supply of Main Base Unit and Extension Base Unit is ON Refer to Section 4 4 1 Check the following items and turn ON power supplies of the power supply modules of the main base units and extension base units Wiring...

Page 71: ...stem Refer to Section 4 8 Power off the system and then power on again or set the RESET L CLR switch of the CPU module to the RESET position and then set it to the reset switch neutral position Error Check Refer to Section 4 9 Check if the ERR LED of the CPU module is OFF If the ERR LED is ON flashing check the error cause using the System Monitor or diagnostics of GX Developer and eliminate it Ru...

Page 72: ... pushing it in the direction of arrow 2 Handling Cautions a Do not drop the module case or subject it to strong impact as it is made of resin b The module can be fixed to the base unit easily by the upper hook However it is recommended that the module be fixed using the module fixing screw if installed in a location exposed to strong vibration or impact In such cases tighten the module fixing scre...

Page 73: ... a main base unit by referring to the wiring example shown in Diagram 4 4 1 Operation of an ERR terminal is as follows When mounting power supply module to main base unit The ERR terminal is OFF open when AC power is not turned ON when the CPU module stop error including an error at the time of reset occurs or when fuse of the power supply module is blown When mounting redundant power supply modul...

Page 74: ...y module 3 When two redundant power supply modules Q64RP are placed together and operated as a redundant power supply system it is recommended to use one of them as an AC power input and connect the other to an uninterruptible power supply 4 When LG terminals and FG terminals are connected be sure to ground the wires Otherwise the PLC may be susceptible to noise Since the LG terminal has a half of...

Page 75: ...ry connectors according to the following procedure prior to use a Confirming Battery Installation Status Open the CPU module bottom cover and confirm that the battery is installed properly b Connecting the Battery Connectors Align the connector mounted in the case with battery connector pin and insert it Remark Refer to the following manual for installation of Q7BAT batteries and SRAM card batteri...

Page 76: ...m A system B b Connecting a Tracking Cable Connector Align the tracking cable connector with the CPU module TRACKING connector and then connect them Make sure to tighten the tracking cable connector fixing screws after connecting the tracking cable Tightening torque 29 4 N cm Diagram 4 6 Connecting a Tracking Cable Connector Diagram 4 7 Fixing a Tracking Cable Connector Redundant CPU Connector Tra...

Page 77: ...t System A extension cable Connect to IN connector IN1 on the redundant type extension base unit System B extension cable Connect to IN connector IN2 on the redundant type extension base unit b Connecting the redundant type extension base unit to the redundant power extension base unit Connect extension cable from OUT connector on the redundant type extension base unit to IN connector on the redun...

Page 78: ...ew driver or other tool this can result in damage 4 4 Confirming that the Power Supply is ON 1 Powering on the system Check the power line and power supply voltage of the power supplies of the power supply modules of the main base units and extension base units in systems A and B and turn ON power supplies simultaneously 2 Confirming the Power Supply Module POWER LED After turning ON power supplie...

Page 79: ...ion 4 6 Starting up Connecting GX Developer 1 Starting up GX Developer Power on the PC and start up GX Developer 2 Connecting GX Developer Connect the computer in which GX Developer has been installed and the System A CPU module with a cable Refer to the following manual for applicable cables QCPU User s Manual Hardware Design Maintenance and Inspection Table4 1 Identify system A and system B by c...

Page 80: ...the following procedures 1 Display of Write to PLC Screen Select Online to Write to PLC from the menu bar to display the Write to PLC screen 2 Selection of Write Data Click the Parameters and Programs button and select parameters and programs as Write Data 3 Execution of Write to PLC Click the Execute button As the following confirmation dialog box appears click Yes Diagram 4 12 Write to PLC Scree...

Page 81: ...ET L CLR switches of system A and system B CPU modules to the RESET position and then simultaneously set the switches to neutral position 2 3 1 Power on one system within three seconds after powering on the other system 2 Set the reset switch of one CPU module to neutral position within three seconds after making the same settings for the other CPU module 3 The LED turns on on either system in the...

Page 82: ... Set the RUN STOP switch to the RUN position in this order standby system System B CPU module control system System A CPU module Table4 2 Checking the ERR LED to Check for Errors CPU Module LED LED common to System A and System B LED Name Normal Error 1 ERR OFF ON Flashing Table4 3 Checking the CONTROL LED to Identify Control System and Standby System CPU Module LED LED common to System A System B...

Page 83: ...T SYSTEM 4 11 Running CPU Modules 4 17 1 OVERVIEW 2 SYSTEM CONFIGURATION 3 TRACKING CABLE 4 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM 5 REDUNDANT SYSTEM FUNCTIONS 6 REDUNDANT SYSTEM NETWORKS 7 PROGRAMMING CAUTIONS 8 TROUBLESHOOTING Memo ...

Page 84: ...odule of either system performs operations and controls the redundant system The other system which is for backup does not perform operations The controlling system is referred to as Control system and the backup system Standby system Please refer to Section 5 1 2 for details on the control system and standby system 3 Switching Between the Control System and Standby System If a fault occurs in the...

Page 85: ...e control system program of standby system can be corrected and operation of program can be checked by using the data tracked from the control system However in the separate mode system switching is not executed even if a fault or failure occurs in the control system System switching can be manually carried out c Debug mode The debug mode is for debugging with a system configuration of only either...

Page 86: ... When the System A connector is connected to the left system When the system A connector is connected to the CPU module of the left system system A B will be determined as shown in Diagram 5 2 b When the System A connector is connected to the right system When the system A connector is connected to the CPU module of the right system system A B will be determined as shown in Diagram 5 3 Refer to CH...

Page 87: ... Precautions When using the redundant system in the backup mode connect the tracking cable to the control system and the standby system CPU modules If both systems are powered on without the tracking cable connected to the CPU models the TRK CABLE ERR error code 6120 stop error will occur and the system cannot run If TRK CABLE ERR occurs at power on power off System A and System B then connect the...

Page 88: ... other one the system that starts up first will be the Control system and the other one will be the Standby system 3 When both CPU modules of the system A and system B are reset the system with the CPU module of which RESET L CLR switch is set to the neutral position first will be the Control system and the other one will be the Standby system 3 a When system A starts up first 1 Refer to Section 5...

Page 89: ...RESET L CLR switch is set to the neutral position simultaneously system A will be the Control system and system B will be the Standby system 4 Refer to Section 5 1 1 for determination of system A and system B 5 This indicates the following cases One system starts up and the other starts up within 3 seconds When one CPU module is unreset RESET L CLR switch is set to the neutral position within 3 se...

Page 90: ...ntify the control system and standby system by checking the CONTROL LEDs of CPU modules Refer to the following manual for details on the CPU module LED QCPU User s Manual Hardware Design Maintenance and Inspection 7 The control system and standby system can be identified by checking whether the special relays Control Standby Status flag SM1515 and Control Standby Status flag SM1516 are ON or OFF D...

Page 91: ...NG CAUTIONS 8 TROUBLESHOOTING 5 Precautions When using the redundant system in the backup mode connect the tracking cable to the control system and the standby system CPU modules If both systems are powered on without the tracking cable connected to the CPU models the TRK CABLE ERR error code 6120 stop error will occur and the system cannot run If TRK CABLE ERR occurs at power on power off System ...

Page 92: ...eration of redundant system If a fault or failure occurs in the control system the standby system takes over the control and continues the system operation To enable the standby system to continue the system operation when the control system goes down the data of the control system must be continuously transferred to the standby system through the tracking cable Refer to Section 5 5 for details on...

Page 93: ...ch is set to the neutral position simultaneously the operation mode will automatically change to the backup mode This applies to only when the debug mode has not been specified in the redundant parameter settings If the above operation is performed when the operation mode has been set to the separate mode with GX Developer while the system is running this also will change the operation mode to the...

Page 94: ...ling the Tracking Function In the separate mode it is possible to select whether the tracking function is enabled or not in order to perform the tracking Refer to Section 5 5 for the tracking function b Confirming the Separate Mode Confirm that the redundant system is running in the backup mode by checking the BACKUP LEDs of CPU modules Refer to the following manual for details on the CPU module L...

Page 95: ...dby system again System switching will not occur even when the control system is powered on again or unreset RESET L CLR switch is set to the neutral position However system switching can be manually carried out Refer to Section 5 3 for details on system switching 3 Do not turn OFF the power supply of the control system or perform reset operation in the separate mode when the extension base unit i...

Page 96: ...irm that the redundant system is running in the debug mode by checking the relevant LEDs of the CPU module Refer to the following manual for details on the CPU module LED QCPU User s Manual Hardware Design Maintenance and Inspection 1 When CC Link IE Controller Network modules are mounted do not connect the CC Link IE Controller Network module on both systems to the network at the same time In the...

Page 97: ... mode is set into the CPU module and power on the system again or set the RESET L CLR switch of the CPU module to reset switch neutral position Then the system will start up in the debug mode 2 Write the redundant parameter in which Do not start with Debug mode is set into the CPU module and power on the system again or set the RESET L CLR switch of the CPU module to reset switch neutral position ...

Page 98: ...are running in the different modes backup mode separate mode and debug mode each of them operate as shown in Table5 8 Cancel the debug mode in the redundant parameter when using the redundancy system in the backup mode 5 In the debug mode the CPU module uses the parameters for system A to operate Therefore the station set as system B in the network parameters becomes absent station disconnected st...

Page 99: ... in the following cases When both systems are powered on simultaneously When both system CPU modules are unreset RESET L CLR switch is set to the neutral position simultaneously During END processing by the control system CPU module When the tracking cable is reconnected Table5 9 shows consistency check points and Table5 10 shows execution conditions Diagram 5 11 Consistency Check Points Between S...

Page 100: ...le5 10 Consistency Check Execution Conditions between System A and System B Conditions 1 Description Execution Timing Operation Mode Standby System Operating Status Control System Operating Status File Operating Status Basic System Configuration Memory Card Settings Parameter Valid Drive Settings Execution Timing Operation Mode StandbySystem Operating Status Control System Operating Status File Op...

Page 101: ...programs and parameters Verify the GX Developer and PX Developer programs and parameters saved in the offline environment with the those written to both system CPU modules 2 If a stop error occurs in the standby CPU module the STANDBY SYS DOWN error code 6300 continuation error will occur in the control system CPU module Table5 11 Target Files and Check Contents Target Files Details Parameters Che...

Page 102: ...g Status Consistency Check Table5 13 Inconsistency Errors Execution Conditions Error Description When both systems are powered ON simultaneously When both system CPU modules are unreset RESET L CLR switch is set to the neutral position simultaneously The following stop error will occur in the control system and standby system CPU modules OPE MODE DIFF error code 6020 When one system starts up afte...

Page 103: ...onsistency at backup mode settings in the redundant parameter settings Then write the parameter to the CPU module reset it and the parameter setting will take effect 2 When Check operating status consistency is unchecked the CPU module will not detect an error even when writing the parameters with GX Developer to change the CPU operating status 3 When powering on both systems simultaneously even i...

Page 104: ...ttings A consistency check is not executed for the followings Model of battery set in the CPU module Main base unit model and number of available slots Serial Nos of modules mounted in the main base unit Number of power supply modules mounted in the main base unit Model of power supply modules mounted in the main base unit Slots set to Open in the PLC parameter I O assignment Modules being replace...

Page 105: ...plicable per system Connect IN connector IN1 and IN2 of the redundant type extension base unit to OUT connector of the main base unit Connect OUT connector of the redundant type extension base unit to IN connector of the redundant power extension base unit The main base units used in systems A and B should be the same model Table5 14 Basic System Configuration Inconsistency Errors Execution Condit...

Page 106: ...set or not Memory Card Type Checks if type of memory cards set in the control system and standby system SRAM card Flash card ATA card are the same Diagram 5 15 Memory Card Setting Status Consistency Check Table5 17 Memory Card Setting status Inconsistency Errors Execution Conditions Error Description When both systems are powered ON simultaneously When both system CPU modules are unreset RESET L C...

Page 107: ...y cards of different capacities check the capacity required for the actual control 2 If the special relay Card removal setting enable flag SM609 is turned on and the memory card is changed during redundant system operation an error does not occur since a memory card setting status consistency check is not performed However a memory card setting status consistency check is executed if both systems ...

Page 108: ...will occur in the control system CPU module STANDBY SYS DOWN error code 6300 Diagram 5 16 Parameter Valid Drive Settings Consistency Check Table5 18 Parameter Valid Drive Settings Inconsistency Errors Execution Conditions Error Description When both systems are powered ON simultaneously When both system CPU modules are unreset RESET L CLR switch is set to the neutral position simultaneously The fo...

Page 109: ...y and special register in a program to make a programmable controller or machine system interlock b Error history confirmation The redundant CPU records the 16 latest error codes as error history The error history can be checked in the PLC diagnostics of GX Developer The error history is backed up by the battery even if the programmable controller is powered off 3 Redundant CPU Operation upon an e...

Page 110: ... 4 Module verify error 5 Intelligent program execution error 6 File access error 7 Memory card operation error 8 External power supply OFF setting for extension in future As the module verify error is preset to stop when the error occurs a stop error is detected in the control system resulting in system switching However since the new control system also detects the module verify error and stops i...

Page 111: ...ity Check Extension base unit mounting check BASE LAY ERROR 2010 to 2013 7 For unsupported module being mounted check SP UNIT VER ERR 2151 8 Main base unit bus check CONTROL BUS ERR 2 1411 9 Extension base unit bus check 1418 10 Extension base unit mounting status EXT CABLE ERR 2020 11 Base assignment check SP UNIT LAY ERR 2122 2125 12 Booting check BOOT ERROR 2210 2211 13 For parameters check MIS...

Page 112: ...edundant parameter settings of GX Developer 1 Initial start mode Default This mode is for clearing all devices except the file register and the latch range settings device word device 0 bit device OFF before performing the operation Diagram 5 17 Operation setting Screen Diagram 5 18 Initial Start Mode Operation Select Initial start mode Hot start mode Power the system off and back on System A Cont...

Page 113: ...ing the operation from when holding the device Some devices such as the step relay and the index register will be cleared As holding the devices even when the redundant system goes down due to power OFF or CPU module reset the system can continue the operation when it is powered on or the CPU modules are unreset RESET L CLR switch is set to the neutral position Diagram 5 19 Hot Start Mode Operatio...

Page 114: ...evice Value Setting Range Initial value is set Local Device Cleared File Register Held Program Execution Initial Execution Type Program Executed only one time during STOP RUN Interrupt Permitted Not Permitted Set to not permit interrupt SM402 After RUN ON for 1 scan Turned ON 1 scan during STOP RUN SM403 After RUN OFF for 1 scan Turned OFF 1 scan during STOP RUN Program Execution Type Initial Scan...

Page 115: ...l system failure or fault occurs Control can be continued with the same data even if a control system failure or fault occurs and the systems switching occurs Section 5 5 Online Program Change for Redundancy This function transfers the data such as programs including those written online and parameters written to the control system CPU from the standby system Section 5 6 Memory Copy from Control S...

Page 116: ...e user Whether the system switching can be executed automatically or manually depends on the operation mode Refer to Section 5 1 3 for details on operation mode Table5 22 indicates the system switching methods and applicable operation modes 1 System switching can be done from the OPS application using EZ Socket too Table5 22 System Switching Method and the Applicable Operation Modes System Switchi...

Page 117: ...the system switching has been executed or not in the PLC diagnostics Error log of GX Developer 2 2 If the WTD error occurs in the new standby system PLC diagnostics cannot be done via the tracking cable Connect an RS 232 cable or USB cable to the system to be diagnosed new control system new standby system and execute the PLC diagnostics The reason for system switching can be confirmed on the Erro...

Page 118: ...the standby system CPU module switches to the control system and continues the redundant system control A stop error occurs in the control system CPU module The control system is powered OFF The control system CPU module is reset If a continuation error occurs in the control system CPU module system switching will not occur Diagram 5 23 shows the processes that take place if a stop error occurs in...

Page 119: ...PROFIBUS DP master module does not request system switching even if the module detects a module fault or communication failure with DP Slaves When receiving the system switching request from the network module the control system CPU module will perform a system switching at END processing Diagram 5 24 shows the processes that take place when the system switching request is received from the networ...

Page 120: ...nnected the system switching may not be performed depending on the timing when the control system and standby system detects the fault Example The following diagram shows the processes that take place when the redundant system is connected to the MELSECNET H If the control system detects the cable disconnection first the system switching will be performed If the standby system detects the cable di...

Page 121: ...X Developer the system switching operation is done at END processing 1 System switching using GX Developer is done in the following procedure Turn on the Enable disable user system switching flag SM1592 in the control system CPU module The system switching request is issued to the control system CPU module by the redundant operation of GX Developer Diagram 5 26 System Switching Operation by GX Dev...

Page 122: ... Turn on the system switching instruction condition in the control system CPU module and execute the instruction 1 Refer to the following manual for details on the system switching instruction MELSEC Q L Programming Manual Common Instruction Diagram 5 27 Error Dialog Box Displayed on GX Developer Diagram 5 28 System Switching Operation by System Switching Instruction System A Control System System...

Page 123: ... use the special relay Standby system to control system switching status flag SM1518 as illustrated in Diagram 5 29 and modify the program so that the instruction will not be executed in the new control system CPU module again 2 The error completion device for the system switching instruction can be used to check whether system switching is executed by the system switching instruction or not When ...

Page 124: ...ty The system switching priorities are shown in Table5 23 a System switching processing when multiple system switching requests are issued simultaneously When multiple system switching requests are issued simultaneously system switching is performed according to the priority from high to low of reasons for system switching Diagram 5 30 Example of System Switching Instruction programming Diagram 5 ...

Page 125: ...itching request is issued to the standby system CPU module the system switching will not be executed Table5 24 indicates the operations performed when a system switching request is issued to the standby system CPU module Diagram 5 32 Error Dialog Box Displayed on GX Developer Table5 24 Operations When a System Switching Request is issued to the standby system CPU Module System Switching Request Op...

Page 126: ...wing manual for details on the COM instruction MELSEC Q L Programming Manual Common Instruction Table5 25 System Switching Execution Timing System Switching Method Reasons for System Switching in Control System Execution Timing Automatic System Switching Stop error System switching is executed when the reason for system switching occurs Power off Reset System switching request by network module Sy...

Page 127: ...2 3 Watchdog timer error corresponds to the WDT ERROR error code 5000 OR 5001 4 The control system switches to the standby system but the standby system status does not change Table5 26 System Switching Execution Capability Standby System Operating Status 1 Control System Switching Condition Automatic System Switching Manual System Switching Stop Error Other Than Watchdog Timer Error Watchdog Time...

Page 128: ...urred Stop Error The CPU module has stopped as a stop error has occurred Power Off The system power is OFF Resetting The CPU module is being reset At network fault detection A fault has been detected by at least one module of standby system network modules CC Link IE Controller Network module MELSECNET H module Ethernet module PROFIBUS DP master module Preparing for Tracking The communication is n...

Page 129: ...o become control system Manual System Switching System Switching Using GX Developer Control System Standby System Control System Standby System Startup as standby system System Switching by System Switching Instruction Control System Standby System Control System Standby System Startup as standby system Table5 29 Operations When System Switching Cannot Be Executed Due to Error Other Than Stop Erro...

Page 130: ...System Standby System System switching will not be executed System Switching by System Switching Instruction Control System Standby System Control System Standby System System switching will not be executed Table5 31 When System Switching Cannot Be Executed Due to Network Error of Standby System System Switching Method Control System Switching Condition System Status Before System Switching System...

Page 131: ...ndby System Standby System Control System Startup as standby system Watchdog Timer Control System Standby System Standby System Standby System Startup as control system Hardware Failure Control System Standby System Standby System Control System Startup as control system Power OFF Control System Standby System Standby System Control System Startup as control system Reseting Control System Standby ...

Page 132: ...ontrol System Switching Condition Automatic System Switching Manual System Switching Stop Error Other Than Watchdog Timer Errors Watchdog Timer Error 2 Hardware Failure Power OFF Reset System Switching requested by the Network Module System Switching Using GX Developer System Switching with System Switching Instruction Normal Continuation Error Power OFF Resetting Hardware Failure Watchdog Timer E...

Page 133: ...em is executing system switching due to the previous system switching condition Table5 35 Operations When System Switching Cannot Be Executed Due to Operation mode i e Separate Mode System Switching Method Control System Switching Condition Before System Switching System Status After System Switching Condition Operation After Changing From Separate Mode to Backup Mode System A System B System A Sy...

Page 134: ... data processing Device Memory Holds the data Holds the data Sets the received tracking data to specified device Signal Flow Memory Holds the tracked data Turns ON signal flow memory in all steps if has not been tracked Stores the execution results in the signal flow memory after program execution Holds the data Sets the received tracking data in the signal flow memory Initial Device Value Setting...

Page 135: ...oller Network Starts cyclic transmission Continues cyclic transmission However does not perform output MELSECNET H PLC to PLC network Starts cyclic transmission Continues cyclic transmission However does not perform output MELSECNET H Remote I O network Starts cyclic transmission Operates as master station Continues cyclic transmission as sub master station However does not perform output Ethernet...

Page 136: ...me of System Switching New Control System CPU Module New Standby System CPU Module SD5 Error common information Stores the system switching condition that occurred in the control system prior to system switching only when 5 System switching condition is saved to error common information category code for SD4 0 No system switching condition default 1 Power OFF reset hardware failure watchdog timer ...

Page 137: ...hen system switching could not be performed is stored in the following values 0 System switching completed successfully 1 Tracking cable malfunction cable disconnection cable malfunction or internal circuit malfunction 2 Hardware failure power OFF resetting or watchdog timer error occurring on standby system 3 Hardware failure power OFF resetting or watchdog timer error occurring on control system...

Page 138: ...rdware failure or watchdog timer error 1 2 Stop error except watchdog timer error 3 System switching request from network module 16 System switching instruction 17 System switching request from GX Developer SD1602 System switching dedicated command parameter Stores command parameter when switching due to SP CONTSW instruction SP CONTSW instruction parameter is stored in SD1602 on both systems at s...

Page 139: ... 40 below If the system switching has failed power OFF the system A and B connect a perfect cable to the CPU module and then power ON the both systems simultaneously With this operation the system A will operates as the control system 2 Monitoring the Watchdog Timer During System Switching The redundant system suspends the watchdog timer from being monitored during system switching Therefore the W...

Page 140: ... GX Developer due to cable disconnection or other reason during online program change the redundant system CPU module cannot complete the online program change and may remain to be disabled from performing system switching As long as the redundant CPU module is in this status either of manual system switching or system switching by network module system switching request cannot be performed In thi...

Page 141: ...ant operation from the menu bar of GX Developer to open the Redundant operation screen 3 Open the GX Developer online Redundancy Procedure window Check the Change operation mode at the redundant operation area and then select Separate mode from the list 4 Click the Execute button 5 Set the RUN STOP switch of the standby system CPU module to RUN STOP RUN or use GX Developer to change from remote ST...

Page 142: ... L CLR switches of both CPU modules to reset switch neutral position simultaneously c Precautions 1 After the operation mode is changed from the separate mode to backup mode the standby system CPU module resumes the Consistency Check Between Systems A and B When returning to the backup mode make sure to make the settings so that the control system and standby system will be consistent in advance R...

Page 143: ...change the mode to separate mode or reset the control system CPU module 3 The operation mode cannot be changed from separate mode to backup mode using GX Developer when the control system CPU module operation is stopped the RUN LED of the CPU module is flashing 4 Operation mode cannot be changed in the following situations When standby system is powered off or the standby system CPU module is bein...

Page 144: ... switching is completed If the error dialog box Diagram 5 39 appears on GX Developer after the system switching repeat the operation mode change When the operation mode change request is issued to the CPU module in the debug mode If the error dialog box Diagram 5 40 appears cancel Debug Mode in the redundancy parameters Section 5 1 3 When a hardware failure or watchdog timer error has occurred in ...

Page 145: ...ion mode During memory copy from control system to standby system If the error dialog box Diagram 5 43 appears on GX Developer wait for memory copy from the control system to the standby system to complete and then change the operation mode When a stop error occurs in the control system CPU module the RUN LED flashing If the error dialog box Diagram 5 44 appears on GX Developer cancel the control ...

Page 146: ... on continues Turns off and then flashing Turns on when the RUN STOP switch is operated from RUN to STOP to RUN Operation status STOP PAUSE stop error Turns off continues Turns off continues BACKUP ON green and then ON orange ON green and then ON orange Other than RUN and BACKUP Takes over the current status Takes over the current status I O I O from to main base unit Input Continues execution Con...

Page 147: ... current setting Takes over the current setting Turns on continues Turns on flickers and then turns off Turns off continues Turns off continues Lit orange and then lit green Lit orange and then lit green Takes over the current setting Takes over the current setting Continues execution Continues execution Continues execution Stops output Continues execution Does not execute input Continues executio...

Page 148: ...ction Data tracking Section 5 5 3 Device memory Continues execution SM SD system dependent Stops tracking SFC information Stops tracking PID control instruction information Stops tracking Signal flow with tracking setting Stops tracking Consistency check between System A B Section 5 1 4 There are no items to be checked when operation mode change is made Stops operation status consistency check bet...

Page 149: ...M NETWORKS 7 PROGRAMMING CAUTIONS 8 TROUBLESHOOTING From Separate Mode to Backup Mode Control system Standby system Continues execution Starts tracking Starts tracking Starts tracking Starts tracking Makes consistency check between System A B for the following items When an error is detected a self diagnostic error occurs in the standby system File Operation status Main base mounting status Parame...

Page 150: ...a Calculating Output Data QnPRHCPU Input data Input data Output Data Input data Start calculation Output Data MELSECNET H Remote I O network Control system Standby system Separate mode Remote I O station Multiplexed Remote Master Station Multiplexed Remote Sub master Station QnPRHCPU Input data Calculating Output Data Multiplexed Remote Master Station QnPRHCPU Input data Input data Output Data Inp...

Page 151: ...peration Mode Change Function 5 68 1 OVERVIEW 2 SYSTEM CONFIGURATION 3 TRACKING CABLE 4 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM 5 REDUNDANT SYSTEM FUNCTIONS 6 REDUNDANT SYSTEM NETWORKS 7 PROGRAMMING CAUTIONS 8 TROUBLESHOOTING Memo ...

Page 152: ... not execute the check Tracking Executes the function Executes the function Does not execute the function Program Change in Ladder Mode During RUN Executable Executes the online program change in the control system Does not execute it in the standby system only Writing files in RUN Executable Executes the function when control system has been rewritten Standby system rewrite only is not possible I...

Page 153: ...ol system Holds Reflects the operation result of the standby system Holds ON OFF ON OFF Executes it Executes it Does not execute the check Does not execute the check Executes the function Executes the function Does not execute function Executes the check on the specified CPU module only Executes only on specified CPU module Executes only on specified CPU module Executes only on specified CPU modul...

Page 154: ...U Module Network Module Executes the function Executes system switching Executes a refresh from the network module to the CPU module Does not execute a refresh from the CPU module to the network module Executes the function Transient Requested from Other Station in CC Link IE Controller Network Executes the function Executes the function Refresh between MELSECNET H PLC to PLC Network CPU Module Ne...

Page 155: ... During Resume Error During Stop During Stop Error During Normal RUN and During Resume Error During Stop During Stop Error Executes the function Does not execute the function Executes refresh from network module to CPU module Does not execute refresh from CPU module to network module Does not execute the function Executes the function Executes the function Executes the function Does not execute th...

Page 156: ...lt in the redundant CPU tracking can be done without changing the tracking settings 1 Tracking can be done in either backup mode or separate mode 2 1 Following tracking data are set by default Internal devices SFC data PID control instruction data Refer to Section 5 3 for the tracking data setting 2 Please refer to Section 5 5 3 for data tracking in the backup mode and separate mode 3 If the data ...

Page 157: ...f the tracking settings The automatic tracking data range cannot be changed by the user Refer to Section 5 5 3 for details on the tracking data settings 3 Changing Tracking Data Settings The tracking data range settings can be changed in the following cases To shorten the tracking time To add to the tracking data file register etc To change the tracking timing in a program To track signal flow mem...

Page 158: ...s occur on the standby system Standby system power is off A stop error occurs on the standby system CPU module The standby system CPU module is resetting Tracking can be performed if reset is cleared When tracking device setting is not made the program is executed with the values before refresh at first scan after system switching Set the following devices as tracking devices Device that makes aut...

Page 159: ...Diagram 5 48 Diagram 5 48 Tracking Execution Procedure Start Completed YES NO Perfom tracking transfer according to defaults Use GX Developer to change tracking setting redundancy parameters Use GX Developer to add tracking forwarding triggers to the controlling program Write to the CPU module parameters set with GX Developer and programs Write to the CPU module parameters set with GX Developer an...

Page 160: ...es that can be tracked 1 Internal Device Default Setting Range The default tracking range is set to the internal devices as shown in Table5 44 When changing the number of the device points to be used in the PLC parameter device setting using GX Developer the number after change will be the tracking range By default all device points in the tracking range are to be tracked Table5 43 Tracking Data S...

Page 161: ...e set by the user 6 Do not perform the tracking transfer to the link special relay SB and link special register SW used in the network module system since they are the data inherent to stations 7 Refer to Section 7 3 for the processing to be performed when the annunciator is tracked Remark Please use the following settings when changing the internal device settings Bit devices including timer rete...

Page 162: ...ng tracked Rise instruction PLS P SP Even if the execution condition is changed from off to on during system switching the rise instruction will not be executed after system switching Fall instruction LDF ANDF ORF MEF PLF If the execution condition is off during system switching the fall instruction will be executed after system switching SCJ instruction If the execution condition is on during sys...

Page 163: ... OFF command SM702 Search method SM206 PAUSE enable coil SM703 Sort order SM210 Clock data set request SM710 CHK instruction priority ranking flag SM213 Clock data read request SM715 EI flag SM250 Max loaded I O read SM722 BIN DBIN instruction error disenabling flag SM254 All stations refresh command SM774 PID bumpless processing for complate derlvative SM255 to SM257 MELSECNET H module 1 informat...

Page 164: ...sts SD207 to SD209 LED display priority ranking SD210 to SD213 Clock data SD250 Loaded maximum I O SD315 Time reserved for communication processing SD414 2n second clock setting SD415 2n ms clock setting SD550 Service interval measurement module SD774 to SD775 PID limit setting for complete derivative SD778 Refresh processing selection with the COM instruction is executed SD794 to SD795 PID limit ...

Page 165: ...erence 1 Tracking device setting Internal device block setting Device detail settings Internal device block setting Section 5 5 3 2 Signal flow memory tracking setting No tracking Enable tracking of signal flow memory No tracking Section 5 5 3 3 Tracking block No 1 to 64 1 Section 5 5 5 4 Device range Settings 1 Device Table5 44 Tracking Range Set by User Table5 44 Default Tracking Range Section 5...

Page 166: ...ter 0 to 32767 set in 16 point units Word device 0 to 32767 set in 1 point units 2 The file register file can be set in each tracking block 3 16 device points of timer retentive timer and counter is equivalent to 18 words POINT 1 The same device No cannot be set in 2 ranges for 1 tracking block If the same device No is set in 2 ranges in the tracking settings of GX Developer an error will occur in...

Page 167: ...ameter settings of GX Developer b Tracking the Tracking Blocks Set whether the tracking block will be tracked or not with the data tracking block specification trigger SM1520 to SM1583 that corresponds to the target tracking block When the data tracking block specification trigger is turned ON the device data set to the corresponding tracking block No will be tracked Diagram 5 50 Tracking Operatio...

Page 168: ...n tracking multiple blocks at a time make sure that the tracking capacity is within 100k words If the tracking capacity exceeds 100k words the continuation error TRK SIZE ERROR error code 6110 will occur and tracking cannot be performed 2 When multiple blocks are set for tracking they will be tracked in the setting order starting from the one of lowest No Diagram 5 51 Tracking device default setti...

Page 169: ...able Tracking ON Enable Tracking When setting batch of internal devices at the tracking Turns on at the time of power ON reset STOP to RUN System User When the detailed device settings are made at the tracking settings The trigger turns on at the time of power ON reset STOP to RUN if tracking block No 1 is set to be tracked in the automatic tracking parameter Turn off if tracking block No 1 is set...

Page 170: ...racking Trigger SM1560 Tracking Block No 41 Tracking Trigger SM1561 Tracking Block No 42 Tracking Trigger SM1562 Tracking Block No 43 Tracking Trigger SM1563 Tracking Block No 44 Tracking Trigger SM1564 Tracking Block No 45 Tracking Trigger SM1565 Tracking Block No 46 Tracking Trigger SM1566 Tracking Block No 47 Tracking Trigger SM1567 Tracking Block No 48 Tracking Trigger SM1568 Tracking Block No...

Page 171: ...ses of both systems 1 In Backup Mode The Tracking target data in the backup mode is shown in theTable5 50 according to the operating statuses of both systems Tracked Not tracked 1 Device data Indicates the internal devices set at the tracking settings in the redundant parameter settings Section 5 5 3 Indicates the special relays and special registers that will be automatically tracked Section 5 5 ...

Page 172: ...dancy parameters tracking setting Section 5 5 3 Special relays and special registers refers to the automatically tracked special relay and special register Section 5 5 3 Table5 51 Tracking Data By System Operating Status Operating Status Tracking Data Control System Standby System Device Data 1 Signal Flow SFC Data PID Control Instruction Data Internal Device Special Relay and Special Register RUN...

Page 173: ...racking mode will change to asynchronous mode when the backup mode is changed to separate mode 2 Tracking mode will change to synchronous mode within maximum 150ms after the separate mode is changed to backup mode 3 When the special relay Device memory tracking during RUN write SM1710 is turned on to execute tracking during online program change tracking during online program change is executed in...

Page 174: ... stands from tracking start to finish and executes the scan execution type program upon tracking completion For this reason when system switching occurs the new control system CPU starts operation based on the scan tracking data of up to 1 scan before However scan time increases by the amount of tracking time Diagram 5 52 Synchronized Tracking Mode Operation Timing Send Receive Send Receive Contro...

Page 175: ...cessing Time Diagram 5 54 Tracking Operation Timing When Program Execution Time Tracking Processing Time 0 1 tracking when program run time tracking time Control system CPU module END Run program 1 END 0 Run program 2 END 0 0 Run program 3 Scan time Prepare Tracking data 1 Prepare Tracking data 2 Prepare Tracking data 3 Tracking processing 1 Adjust Tracking data 1 Tracking processing 2 Adjust Trac...

Page 176: ...ntrol system CPU module END Run program 1 END 0 Run program 2 END 0 0 Run program 3 Scan time Prepare Tracking data 1 Prepare Tracking data 2 Prepare Tracking data 3 Tracking processing 1 Adjust Tracking data 1 Tracking processing 2 Adjust Tracking data 2 Tracking processing 3 Device data for new control system CPU module Run program Non executed END Error occurrence Incomplete Send Receive Send R...

Page 177: ...ion Timing in Separate Mode Control system CPU module END END 0 Run program 1 END END 0 0 Run program 2 END END 0 0 0 Run program 3 Run program 4 END 0 Run program 5 Run program 6 Scan time Prepare Tracking data 1 Run program 1 Run program 2 END 0 Run program 3 Run program 4 Prepare Tracking data 2 Adjust Tracking data 1 Adjust Tracking data 2 Prepare Tracking data 3 Tracking processing 1 Tracking...

Page 178: ...ode Table5 53 Device Data Used by New Control System CPU Module System Switching Timing Tracking Data Not Received Tracking Data Received Receiving Tracking Data Reception of Tracking Data Completed 1 Device in which Initial Value is not set CPU Module Device Data CPU Module Device Data Received Tracking Data Device in which Initial Device Value is set Preset Initial Device Data CPU Module Device ...

Page 179: ...the parameters and programs either system CPU module GX Developer will write the same parameters and programs to the other system as well 2 Procedure for Writing to the Control System and Standby System GX Developer writes to the control system first and then the standby system regardless of connection route i e the system to which GX Developer is connected The following diagram shows the writing ...

Page 180: ...orm the following operations in either control system or standby system during online program change System power OFF CPU module reset Tracking cable connection or disconnection If any of the above operations is performed Consistency check between system A and B may cause the FILE DIFF error code 6000 stop error in the standby system CPU module In addition the error dialog box in Diagram 5 61 will...

Page 181: ...s again after the writing operation has been completed e Data cannot be written to files being accessed by other GX Developers If data is written to the files being accessed by other GX Developers the error dialog box in Diagram 5 63 will appear Redo the PLC write after completion of the processing performed during access by other GX Developers f Write Processing in Separate Mode In the separate m...

Page 182: ...digits of serial number for the Redundant CPUs is 09101 or lower GX Developer version is 8 58L or later Clicking the OK button displays the following error dialog box Replace the Redundant CPU by the one whose first five digits of serial number is 09102 or higher Diagram 5 64 Error dialog box appearing on GX Developer Diagram 5 65 First five digits of serial number for the Diagram 5 66 First five ...

Page 183: ...he control system during the online program change and system switching occurs the online program change to both systems will continue 2 Procedure for Writing to the Control System and Standby System When performing the online program change to the control system CPU module by GX Developer regardless of the connection route When the online program change is performed to the control system CPU modu...

Page 184: ...flag to enable or disable the tracking execution of the following control data during online program change Internal device Table5 44 Special relay Table5 46 Special register Table5 47 SFC data Section 5 5 3 2 PID control instruction data Section 5 5 3 2 Make sure to set SM1710 to on or off whether or not to execute tracking before executing online program change If the special relay is turned on ...

Page 185: ...ime of the system switching Diagram 5 66 Operation When System Switching Occurs during Online Program Change M0 Y100 Control system System A CPU module M0 Y100 M0 Y100 M0 Y100 Standby system System B CPU module OFF ON OFF ON Abort tracking transfer due to run write operation requested from within GX Developer M0 Y100 M0 Y100 Refresh to the network module Control system Standby System M0 Y100 M0 Y1...

Page 186: ...ystem B CPU module OFF ON M0 Y100 M0 Y100 Refresh to the network module Control system Standby System M0 Y100 M0 Y100 M0 Y100 M0 Y100 Standby system Control System M0 Y100 M0 Y100 Refresh to the network module Refresh to the network module Circuit before program change in ladder mode during RUN Y100 external output Circuit is added to System A CPU module When M0 is set to ON Y100 is also set to ON...

Page 187: ...n changed due to the system switching timing the data calculated in the previous control system after system switching may be tracked Diagram 5 68 Program and Device Data due to System Switching Timing Control system System A CPU module Device data Program Program Perform write during RUN Standby system System B CPU module Device data Perform write during RUN Data before changing Data after change...

Page 188: ...nline program change and enables the online program change again when a communication error occurs between GX Developer and the control system standby system CPU module When the time from when the online program change to the control system is completed until the online program change to the standby system starts falls outside the SD1710 setting range this function judges it as a communication err...

Page 189: ...ange redundant tracking Device memory Including SM SD that will automatically execute tracking PID control command information SFC information 2 This relay can be also used to set whether tracking is to be executed or not in the multiple block online program change or online file writing redundant tracking execution status 3 This SM is also transferred form control system CPU module to standby sys...

Page 190: ...ting files in RUN the same kind of memory is used for the control and standby system CPU modules If different memories are reserved for them writing files in RUN is not executed When writing files in RUN fails the error dialog box in Diagram 5 70 appears c Operations disabled during online program change Do not perform the following operation during online program change System power OFF CPU modul...

Page 191: ...2 will appear on GX Developer Access the programs again after the online program change is complete f When online program change cannot be executed to either control system or standby system In the following cases online program change cannot be executed to either control system or standby system 1 Online program change when a fault has occurred in the standby system The error dialog box illustrat...

Page 192: ... program change is executed the control system CPU module scan time will extended Refer to the following manual for information on control system CPU module scan time extension QCPU User s Manual Function Explanation Program Fundamentals i Signal Flow Processing The signal flow in the changed steps or program turns on Therefore if a running program is changed online the rise fall and SCJ instructi...

Page 193: ... to the neutral position Either control system or standby system is powered OFF and then ON The tracking cable is disconnected and then connected 2 Operating Status Consistency Check The operation status consistency check cannot be performed during online program change 3 Main base unit configuration The main base unit configuration check cannot be performed during online program change However if...

Page 194: ...rol system consistent The applicable memory is standard RAM standard ROM and program memory Memory cards are irrelevant This function is used to make the memory contents of the control system and standby system CPU modules consistent when replacing the standby system CPU module etc a Executing memory copy Memory copy can be executed using either of the followings GX Developer Special relays and sp...

Page 195: ... on during memory copy This relay turns off after memory copy 1 System Applicable to both control system and standby system CPU modules SM1597 This relay turns on after memory copy 1 Turn off this relay when starting memory copy In the case of memory copy by GX Developer GX Developer will turn off this relay before starting memory copy System User Applicable to both control system and standby syst...

Page 196: ... system or standby system CPU module Disconnect the tracking cable If the following error occurs during memory copy the memory copy is also stopped with the memory contents of the standby system CPU module being illegal Tracking cable fault d How to confirm memory copy completion Completion of memory copy can be confirmed by the special relays and GX Developer 1 Confirmation by special relays When...

Page 197: ...ntrol system and standby system CPU modules with a tracking cable and power on the standby system 2 If the standby system CPU module is replaced and the parameters are not stored in the new CPU module the MISSING PARA error code 2200 stop error will occur 2 Connect GX Developer to the control system CPU module Identify the control system CPU module on the CONTROL LED or with the special relay SM15...

Page 198: ...uation error will occur in the control system CPU module and then the STANDBY SYS DOWN error code 6300 continuation error will occur 4 When memory copy begins the PRG MEM CLEAR error code 6400 stop error will occur in the standby system CPU module Diagram 5 80 Redundant Operation Screen Diagram 5 81 Confirmation Dialog Box Displayed on GX Developer Diagram 5 82 LED Indications during Memory Copy S...

Page 199: ...will operate as the standby system CPU module Then the BACKUP LED of the standby system CPU module will turn on green Diagram 5 83 LED Indications at Memory Copy Completion Diagram 5 84 LED Indications during Standby System CPU Module Operation Q12PRHCPU MODE RUN ERR USER BAT BOOT BACKUP CONTROL SYSTEMA SYSTEMB Q12PRHCPU MODE RUN ERR USER BAT BOOT BACKUP CONTROL SYSTEMA SYSTEMB Control system CPU ...

Page 200: ...odule the MISSING PARA error code 2200 stop error will occur 2 Make sure SM1596 and SM1597 are turned OFF If SM1596 or SM1597 is ON turn it OFF Diagram 5 85 shows the operation performed when memory copy is executed Diagram 5 86 LED Indications when Tracking Cable Is Connect Control system Standby system Tracking cable Specify memory copy GX Developer Control system Standby system Tracking cable P...

Page 201: ...system CPU module will turn ON red 5 After completing memory copy to the other system restart the standby system or reset the standby system CPU module It will operate as the standby system CPU module Then the BACKUP LED of the standby system CPU module will turn ON green Diagram 5 87 LED Indications during Memory Copy Diagram 5 88 LED Indications at Memory Copy Completion Diagram 5 89 LED Indicat...

Page 202: ...Diagram 5 91 Memory Copy Special Relay and Special Register Status Display devices Control system Standby system Tracking cable Memory copy preparation Control system Standby system Tracking cable Perform memory copy Control system Standby system Tracking cable Memory copy complete 1 Be sure that SM1596 SM1597 are OFF and store 3D1H in SD1595 Turn ON SM1595 2 Begin memory copy SM1596 ON 3 Memory c...

Page 203: ...ompletion flag SM1597 is ON memory copy will not be to other system status executed even if the Memory copy to other system start flag SM1595 is turned ON In this case no error code will not be stored in Memory copy target I O No SD1596 in the special register Turn OFF SM1596 or SM1597 if either of them is ON then execute memory copy again 2 When a transfer target I O No other than the standby CPU...

Page 204: ...m or the standby system during memory copy 1 PC remote formatting 2 Program memory to ROM 3 PC write flash ROM 4 CPU module write during RUN 5 System switching 6 Operation mode change Table5 59 Error Occurrence During Memory Copy Cause Memory Copy Using GX Developer Memory Copy Using Special Relays and Special Registers Control system power OFF Control system CPU reset The following error dialog b...

Page 205: ...or dialog box will appear Memory copy executed in Debug Mode The following error dialog box will appear 424DH will be stored in SD1596 of the control system CPU Memory copy re executed during memory copy The following error dialog box will appear 4247H will be stored in SD1596 of the control system CPU During online program change or similar operation to the control system CPU module The following...

Page 206: ...is powered off When powering the standby system OFF the STANDBY SYS DOWN error code 6300 continuation error will occur in the control system CPU module 1 Module mounted to the extension base unit The online module change hot swapping is applicable for a module mounted to the extension base unit However there are restrictions on the module where the online module change is applicable For modules th...

Page 207: ...dule supplies power to the modules mounted on the same base unit the redundant system control can be continued during the replacement Refer to Section 8 3 3 for details 4 I O module mounted to main base unit where Redundant CPU is mounted The I O modules mounted on the control system and standby system main base units can be replaced online If an error occurs in an I O module mounted on the contro...

Page 208: ...tworks with network module redundant group settings Diagram 5 93 the processes that take place when a malfunction occurs on both networks with network module redundant group settings Diagram 5 92 Operation When Error Occurs on One of the Networks Diagram 5 93 Operation When Error Occurs on Both Networks System A System B Tracking cable Control system Standby system System A System B Tracking cable...

Page 209: ...he module No corresponds to the slot number on the main base unit Module No 0 Slot 0 Module No 1 Slot 1 Module No 2 Slot 2 Module No 11 Slot 11 4 When a non redundant network module is set in the redundant group settings If redundant group settings are made for a network module that does not support redundant systems a stop error PARAMETER ERROR error code 3000 will occur In this case check the ne...

Page 210: ...Redundant CPU can forcibly turn ON OFF the enforced ON OFF of external I O operation from GX Developer The registered ON OFF information can be cleared by GX Developer operation 1 CPU modules that can be forcibly turned ON OFF The enforced ON OFF of the external I O can be executed for only the control system CPU module It cannot be executed for the standby system CPU If registration change clear ...

Page 211: ...ation before operation mode change remains Hence if the operation mode is changed the external I O forced ON OFF can be continued according to the forced ON OFF information before operation mode change If the operation mode is in the separate mode the external I O forced ON OFF by GX Developer can be executed for only the control system CPU module If in the separate mode the external I O forced ON...

Page 212: ...e standby system CPU module is reset the forced ON OFF information of the control system CPU module does not change The input output of which forced ON OFF has been registered continues the ON OFF status according to the forced ON OFF information of the control system CPU module Table5 61 Operation When Control System Is Powered Off and Then On Control System CPU Module Is Reset and Then its RESET...

Page 213: ...h forced ON OFF has been registered remains the ON OFF status according to the forced ON OFF information of the control system CPU module 3 Turning power supply OFF or reset operation when the extension base unit is connected Do not turn OFF the power supply of the control system or perform reset operation in the separate mode when the extension base unit is connected If doing so turn ON both syst...

Page 214: ... mode 1 Remote RUN remote STOP remote PAUSE or remote latch clear can change the operation status of the CPU module s in the system or both systems specified in the Connection Setup of GX Developer or other means 2 Remote reset can be executed for only the control system CPU module Performing remote reset for the control system CPU module resets both systems b In the separate mode Remote operation...

Page 215: ...cution destination area on the Remote operation screen of GX Developer remote operation is performed for only the system specified in the Connection Setup which can be selected from Online from the menu bar of GX Developer The current station can be selected in the backup mode and separate mode For example when remote STOP is executed after the control system is specified on the Connection Setup s...

Page 216: ...s can be selected in the backup mode only In the separate mode Both systems cannot be selected at the execution destination area on the Remote operation screen of GX Developer When Both systems A B is selected GX Developer executes remote operation in order of the standby system CPU module and control system CPU module Diagram 5 100 Remote STOP Operation When Both Systems Are Specified Control sys...

Page 217: ...set operation a In the backup mode In the backup mode performing remote reset operation for the control system resets both systems Both systems are reset also when Currently specified station is selected at the execution destination area on the Remote operation screen of GX Developer Diagram 5 101 Remote Reset Operation Control system Standby system Control system Standby system GX Developer GX De...

Page 218: ...ram 5 102 will appear b In the separate mode or debug mode In the separate mode or debug mode remote reset can be executed for only the system specified in the Connection setup of GX Developer The operation status of the unspecified system does not change Diagram 5 102 Error Dialog Box Displayed on GX Developer Diagram 5 103 Remote Reset Operation in Separate Mode Control system Standby system Con...

Page 219: ... STOP status and standby system CPU module is in the RUN status System switching will occur when remote reset operation is performed for the control system CPU module when the control system CPU module is in the STOP status and the standby system CPU module is in the RUN status To disable system switching at the time of remote reset change the operation statuses of the control system and standby s...

Page 220: ...dule is reset and the standby system CPU module is not reset When performing remote reset for the standby system CPU module in which a watchdog timer error has occurred set the communication route where the tracking cable is not relayed Diagram 5 105 Remote Reset Operation When Watchdog Timer Error Has Occurred in Standby System CPU Module Control system Standby system Control system Standby syste...

Page 221: ...or the control system or standby system CPU module cancel the remote operation for the standby system CPU module from GX Developer or other means that executed the remote operation for the standby system CPU module 1 How to confirm remote operation execution Whether remote operation has been executed or not can be checked by the special register CPU operation status SD203 When the CPU operation st...

Page 222: ...h of intelligent function module Executable Executable Inexecutable Inexecutable Refresh of CC Link IE Controller Network module Inexecutable 1 Inexecutable 1 Inexecutable 1 Inexecutable 1 Refresh of MELSECNET H module Inexecutable 1 Inexecutable 1 Inexecutable 1 Inexecutable 1 Refresh of CC Link master module Executable Executable Inexecutable Inexecutable Device initial value of link direct devi...

Page 223: ...o a module mounted on the extension base unit from the standby system is disabled When buffer memory batch monitor or device batch monitor is executed from GX Developer the following message box is displayed 5 Input X from the input module on the extension base unit will be an undefined value Table5 65 Access to Module Mounted on Extension Base Unit Continued Item Execution timing Name Access from...

Page 224: ...with GX Developer The communication between GX Developer and redundant CPU module can be made through the following three paths CPU module direct connection Routing a network module Routing an intelligent function module In the case of GX Developer select Online Specify Connection from the menu bar and specify the connection path on the displayed dialog box And specify the communication target sys...

Page 225: ...dule connected to GX Developer is system A communication is done with that CPU module If the CPU module connected to GX Developer is system B communication is done with the other system system A via the tracking cable System B Select this option to communicate with system B CPU module using GX Developer If system switching occurs communication continues with the new system B CPU module If the CPU ...

Page 226: ... current communication target CPU module and the connection path can be confirmed on the following GX Developer screen Diagram 6 2 GX Developer Ladder Monitor Screen Display information for the connected system in monitor status control system standby system and System A System B Display information for the system specified in connection settings control system standby system and System A System B...

Page 227: ...le to which GX Developer PX Developer is connected is different from the specified system communication is done with the CPU module of the other system specified system via the tracking cable Table6 1 b Accessing a Network Module via a Tracking Cable Communication with a network module on the other system via a tracking cable is not available for GX Developer and PX Developer To communicate with a...

Page 228: ...loper However there are restrictions on applicable functions For details refer to the following manuals GX Developer Version 8 Operating Manual PX Developer Version 1 Operating Manual Programming Tool b In the case of monitoring When a line down occurs during access via a network using PX Developer monitoring tool take the corrective action according to the system specified in the connection setup...

Page 229: ... route system s power supply is on and the tracking cable is connected properly Communication via a tracking cable is not carried out in the following cases When the route system s power supply is off When the route CPU module is reset When a watchdog timer error occurs in the route CPU module When the connected system s power supply is off When the connected CPU module is reset When a watchdog ti...

Page 230: ...following manual Q Corresponding MELSECNET H Network System Reference Manual PLC to PLC network The above networks can continue the data link and communication with external devices even when an error occurs in the control system However system switching does not occur when an error occurs in the CC Link The system switching dedicated instruction is necessary to perform system switching Refer to t...

Page 231: ...ion QCPU Normal station AnNCPU Normal station QCPU Normal station QCPU Normal station Personal computer QnACPU Normal station Q4ARCPU Normal station Control station Intelligent Device Station Ethernet Tracking cable System A Control System System B Standby System Multiplexed Remote Master Station Multiplexed Remote Sub master Station Master station Standby Master station GX Developer Remote I O st...

Page 232: ...odules In a redundant system the control system network module carries out cyclic data communication as the control system and standby system form one system The standby system network module receives cyclic data from the other station in order to continue control even when system switching occurs Diagram 6 7 Communication between Control System and Standby System Network Modules Receive only Send...

Page 233: ...occurs in the control system CPU module on the assumption that the control system network module is the control station of station No 1 and the standby system network module is the normal station of station No 2 Diagram 6 8 Operation When System Switching Occurs Due to Control System Error Control system CC Link IE Controller Network CC Link IE Controller Network Standby system Stop Error has occu...

Page 234: ...g to the following procedure so that the data link will be continued 1 When detecting a communication error the control system network module issues a system switching request to the control system CPU module 2 When receiving the system switching request from the network module the control CPU module performs END processing Through the processing system switching is performed 3 After system switch...

Page 235: ... 1 and the standby system network module is the normal station of station No 2 Diagram 6 9 Continuation of Data Link via System Switching CC Link IE Controller Network CC Link IE Controller Network Control system Standby system Normal station Station No 3 Normal station Station No 4 Normal station Station No 3 Operation when a communication error occurs in the MELSECNET H PLC to PLC network Standb...

Page 236: ...eared the new standby system network module is returned to the network as the normal station 4 Station No Settings for the Network Module Set the station Nos for network modules mounted on system A and system B of a redundant system with consecutive numbers Example If station No 3 is set for system A network module system B network module can be set as station No 2 or station No 4 Diagram 6 10 Sta...

Page 237: ...as the systems form a redundant system For the control stations of network systems connected to a redundant system make sure to make the pairing settings for the station Nos of the network modules of system A and system B in the network parameter settings 1 1 In the debug mode the CPU module uses the parameters for system A to operate Therefore the station set as system B in the network parameters...

Page 238: ...be made with the Q4ARCPU in the CC Link IE Controller Network 6 Startup Order of System A and System B No restrictions apply to the startup order of system A and system B when connected to the CC Link IE Controller Network or MELSECNET H PLC to PLC network After starting up system A and system B the control system and standby system are determined and then the data link is continued Diagram 6 12 C...

Page 239: ...roller Network interface board or MELSECNET H board is mounted CC Link IE Controller Network module or MELSECNET H module of the control system may issue a system switching request detecting a temporary communication error When the above mentioned system switching request is issued before the standby system is started up a continuation error CAN T SWITCH may be detected in the control system CPU m...

Page 240: ...multiplexed remote master station performs data control with remote I O station by data transmission and data transmission with the multiplexed remote sub master station The standby system network module multiplexed remote sub master station receives data from remote I O stations and sends receives data to from the multiplexed remote master station in order to take over the control of remote I O s...

Page 241: ... occurs in the control system CPU module Diagram 6 14 Redundant System Operation at System Switching Control system Standby system Tracking cable Tracking cable MELSECNET H Remote I O network Remote I O station station No 3 Remote I O station station No 2 Control system Standby system MELSECNET H Remote I O network Stop Remote I O station station No 3 Remote I O station station No 2 Output is pres...

Page 242: ...formed according to the following procedure so that the data link will be continued 1 When a communication error occurs in the MELSECNET H remote I O network the control system network module issues a system switching request to the control system CPU module 2 When receiving the system switching request from the network module the control system CPU module performs END processing Through the proce...

Page 243: ...e standby system network module is the sub master station Diagram 6 15 Output Status during System Switching Control system Standby system Tracking cable Tracking cable MELSECNET H Remote I O network Remote I O station station No 3 Remote I O station station No 2 Control system Standby system MELSECNET H Remote I O network Remote I O station station No 3 Remote I O station station No 2 Output is p...

Page 244: ... network type identically as MNET H multiplexed remote master 1 1 In the debug mode the CPU module uses the parameters for system A to operate Therefore the station set as system B in the network parameters becomes absent station disconnected station Refer to the following manual for network parameters Q Compatible MELSECNET H Network System Reference Manual Remote I O Network Diagram 6 16 Network...

Page 245: ...nnected to the MELSECNET H remote I O network After starting up system A and system B the control system and standby system are determined and then the data link is started 7 Checking the Standby System Operating Status After power ON the status of a MELSECNET H module on the standby system can be checked with the following link special relays SB on the control system CPU module side SB0075 Remote...

Page 246: ...ork that uses optical cables when a disconnection occurs simultaneously at the following locations Between the master station and sub master station Other than above location In the diagram below the UNIT LAY DIFF occurs when a disconnection occurs simultaneously at point A and any of point B to D Table6 2 shows the transmission possibilities when a disconnection occurs at Point A only and when a ...

Page 247: ...ta link and output status of the remote I O station determined by the combination of the parameter settings a Operation when error occurs in Redundant CPU remote master station 2 Refer to the following manual for details of the PLC RAS setting QCPU User s Manual Function Explanation Program Fundamentals 3 Set the output mode for error occurrence in the I O assignment detailed setting of the PLC pa...

Page 248: ...uest detecting a temporary communication error When the above mentioned system switching request is issued before the standby system is started up a continuation error CAN T SWITCH may be detected in the control system CPU module In this case control can be continued normally Therefore create the program so that control will not be stopped due to error detection For canceling the error CAN T SWITC...

Page 249: ...S connection Refer to the following manual below for details Q Corresponding Ethernet Interface Module User s Manual Basic 1 Indicates the FA communication middleware for programmable controllers servos robots NC etc made by Mitsubishi Electric which consists of the Windows API Application Programming Interface By using EZ Socket each partner company can easily develop FA related application softw...

Page 250: ...net module The system switching request can be set to be issued or not in the network parameters as indicated in 3 1 Only the QJ71E71 100 can detect disconnection Remark A system switching request is not issued when Ethernet interface module is mounted to the extension base unit Diagram 6 21 Operation when a communication error or disconnection is detected System A Control System System B Standby ...

Page 251: ...te with the control system Ethernet module only as processing via sequence programs is necessary 2 External Device Operation at System Switching When system switching occurs in a redundant system external devices operate differently according to the communication method a In the case of OPS connection When system switching occurs in a redundant system the OPS automatically switches the connection ...

Page 252: ...gs IP address station No and mode of Ethernet are set in Redundant settings of the network parameter in the redundant system a When mounting to the main base unit When mounting to the main base unit set Network type as Ethernet Main base b When mounting to the extension base unit When mounting to the extension base unit set Network type as Ethernet Extension base Write the set network parameters t...

Page 253: ...tem Master Local Module User s Manual POINT Auto refresh can be made when mounting the CC Link master module to the extension base unit Set the tracking device setting to the device where the auto refresh is performed When using the auto refresh set Refresh settings of the network parameter Set the tracking device setting to the device where the auto refresh is set Diagram 6 24 CC Link Operation a...

Page 254: ...ata from the remote stations and sends receives data to from the master station in order to continue the CC Link control even when system switching occurs Diagram 6 25 Control of and Data Communication with Remote Stations Power supply module System A Control System Master station Power supply module System B Standby System Standby Master station Tracking cable Remote I O station Remote device sta...

Page 255: ... the new control system standby master station starts to operate as the master station and takes over the control of the remote stations Diagram 6 26 shows the redundant system operation when a stop error occurs in the control system CPU module Diagram 6 26 Operation at System Switching due to Control System Error Master Station Station No 0 Standby Station Station No 1 Standby Master Station Oper...

Page 256: ...n As a result the new control system is unable to control the CC Link Make sure to switch the data link control from the standby master station to the master station using the new control system s program Refer to Appendix 4 for program details Diagram 6 27 Operation at System Switching due to Communication Error of Network other than CC Link Master Station Station No 0 Standby Station Station No ...

Page 257: ...so the new standby system master station remains as the standby station and cannot control remote stations as the master station As a result the new control system is unable to control the CC Link Make sure to switch the data link control from the standby master station to the master station using the new control system s program Refer to Appendix 4 for program details Diagram 6 28 Operation When ...

Page 258: ...ystem Start up a The QJ61BT11N whose first 5 digits of serial No is 07112 or later When using the CC Link control by the CC Link is enabled when starting up either system A or system B b The QJ61BT11N whose first 5 digits of serial No is 07111 or earlier When the redundant system is connected to CC Link start up the system so that system A will be the control system Control via CC Link cannot be p...

Page 259: ...n output is held until system switching is completed The remote station cannot be controlled from when system switching occurs until it is completed Use the expression shown in Table6 5 to calculate the remote station output holding time output holding time at system switching occurrence 1 Use the value in Table6 6 as the error detection processing time Table6 5 Remote Station Output Holding Time ...

Page 260: ...tion module to external devices can be made by MC protocol nonprocedural protocol and bidirectional protocol For MC protocol external devices can communicate with the specified system i e control system standby system system A or system B Refer to the following manual for MC protocol Q Corresponding MELSEC Communication Protocol Reference Manual POINT When the extension base unit is mounted to the...

Page 261: ...the connection destination depending on the command from the external device to MC protocol Appendix 7 1 In addition when system switching occurs the communication timeout will occur since both old system and new system cannot respond Therefore perform retry processing by MC protocol Diagram 6 29 Operation for Communication with Control System CPU Module by MC Protocol Tracking cable Control syste...

Page 262: ...ith external devices can be performed using the control system CPU module s programs Diagram 6 30 Operation for Communication with Control System CPU Module by MC Protocol MELSECNET H Remote I O network Tracking cable Control system Standby system Multiplexed Remote Master Station Remote I O module Serial communication module Multiplexed Remote Sub master Station System switching activated Remote ...

Page 263: ...he new standby system CPU module can be performed even when system switching occurs Communication can be performed by MC protocol only Diagram 6 31 Operation for Communication with Standby System CPU Module by MC Protocol MELSECNET H Remote I O network Tracking cable Standby system Control system Multiplexed Remote Master Station Remote I O module Serial communication module Multiplexed Remote Sub...

Page 264: ... can be performed by MC protocol only Diagram 6 32 Communication with System A CPU Module by MC Protocol MELSECNET H Remote I O network Tracking cable System A Control System System B Standby System Multiplexed Remote Master Station Remote I O module Serial communication module Multiplexed Remote Sub master Station System switching activated Remote I O station Remote I O station MELSECNET H Remote...

Page 265: ...system master module and inherits the PROFIBUS communications 2 Operation at system switching The PROFIBUS DP master modules switch each system on the following cases When the PROFIBUS DP master module detects a fault When a communication failure with DP Slaves is detected Diagram 6 33 Operation of the PROFIBUS DP Master Module at System Switching Tracking cable Control system DP Slave DP Slave St...

Page 266: ...d After the both system is started up and assigned their system Control system standby system data link is started 6 Precautions when using the PROFIBUS DP master modules in redundant system a Function version of the PROFIBUS DP master modules Use the PROFIBUS DP master modules of function version D or later b GX Developer version Use GX Developer version 8 17T or later c At redundant system start...

Page 267: ... Main base unit where Redundant CPU is mounted Bus connection Not connectable since the stop error EXTEND BASE ERR error code 2010 1 occurs to the CPU module CPU direct connection Computer link connection Not connectable since the serial communication module cannot be mounted to the main base unit where the Redundant CPU is mounted Ethernet connection CC Link IE Controller Network MELSECNET H PLC ...

Page 268: ... GOT1000 Series GOT A900 Series Ethernet connection GOT1000 Series CC Link IE Controller Network connection GOT1000 Series GOT A900 Series MELSECNET H PLC to PLC network GOT1000 Series GOT A900 Series CC Link connected Remote I O station Remote I O station Remote I O module Serial communication module Tracking cable GOT1000 Series GOT A900 Series CPU directly connected GOT1000 Series Computer link...

Page 269: ... I O station bus connection When connected to the base unit of a remote I O station the GOT will result in a communication error 1 GOT connection methods Make sure to connect GOTs to a remote I O station via CPU direct connection or computer link connection For CPU direct connection connect the GOT to the remote I O module mounted on the remote I O station via the RS 232 port For computer link con...

Page 270: ...emote I O module communicates with the network module which operates as the master station by specifying station No 0 in the GOT Even when system switching occurs the remote I O module communicates with the network module which operates as the master station in the new control system Therefore the GOT communicates with the new control system CPU module For details refer to the following manual GOT...

Page 271: ... GOT and then connect it to the CC Link 2 Communication method The GOT communicates with the control system CPU module of the master station by specifying station No 0 in the GOT Even when system switching occurs the network module of the new control system operates as the master station Therefore the GOT communicates with the new control system CPU module When connection is made via the extension...

Page 272: ... of the redundant system by setting the Q redundant setting The monitoring target can be changed automatically even when system switching occurs For the function to enable this automatic changing of the monitoring target at the GOT refer to the following manual GOT1000 Series Connection Manual Mitsubishi Products b GOT A900 series The GOT specifies the target communication station connected to the...

Page 273: ... is connected to Ethernet module mounted on the main base unit or Ethernet module mounted on the extension base unit 1 GOT Connection Methods Connect GOTs to a Ethernet via Ethernet connection Diagram 6 38 GOT Connection Type when Mounting to Main Base Unit Diagram 6 39 GOT Connection Type when Mounting to Extension Base Unit Ethernet GOT1000 series GOT A900 series Ethernet connection System B Sta...

Page 274: ...is automatic changing of the monitoring target at the GOT refer to the following manual GOT1000 Series Connection Manual Mitsubishi Products b GOT A900 series The GOT specifies the target communication station connected to Ethernet by the network No and station No It is necessary to specify the station No of systems A and B when communicating with the redundant system in the GOT It is also necessa...

Page 275: ... redundant CPU by specifying control system standby system System A or System B Note that when accessing a redundant CPU from another network network of different network No there are the following restrictions on the CPU modules that can be used as relay stations Table6 8 Applicable Inapplicable Table6 8 CPU Modules Applicable to Relay Stations for Communication with Redundant CPU from Other Netw...

Page 276: ...napplicable GX Developer Control system specified Ethernet network No 4 Control system Standby system MC protocol Control system specified Relay stations MELSECNET H PLC to PLC network network No 1 MELSECNET H PLC to PLC network network No 5 MELSECNET H PLC to PLC network network No 3 Relay station MELSECNET H PLC to PLC network network No 2 QCPU can communicate with Redundant CPU regardless of se...

Page 277: ...stem CPU module reset Control system hardware fault Control system CPU module stop error At this time the new control system CPU module after system switching uses the old device data for control 2 Checking for system switching after device data write After writing device data to the control system CPU module by GX Developer or other means check for system switching occurrence System switching can...

Page 278: ... identification Flags Specify the control system and read the following special relays System A identification flag SM1511 System B identification flag SM1512 Specify the control system and read the following special relays System A identification flag SM1511 System B identification flag SM1512 Specify the control system and write device data Start End Can the data be read normally Are the SM1511 ...

Page 279: ...rtain number of scans from start to completion of the execution If system switching conditions are satisfied while this kind of instruction is being executed the CPU stops the execution and the relevant processings will not be completed In this case it is necessary to use the user program to execute that instruction again after system switching 1 Refer to the manual of the intelligent function mod...

Page 280: ...set for tracking Diagram 7 1 System Configuration Table7 2 Devices Used for Execution of REMFR Instruction Device No Name Remarks SB20 Module status Refer to the following manual for details of the link special relays SB and link special registers SW Q Corresponding MELSECNET H Network System Reference Manual Remote I O Network SB47 Baton pass status of host SB48 Status of host SB49 Data link stat...

Page 281: ...ne if its execution is completed or not However note that the same instruction might be executed twice Diagram 7 2 Example of REMFR instruction programming Turns ON M202 when system switching occurs during execution of the REMFR instruction Turns ON M201 to execute the REMFR instruction when M200 or M202 is ON the MELSECNET H remote I O network is normal and normal communication can be made with t...

Page 282: ... is satisfied before the systems are switched b Relevant Instructions LDP ANDP ORP MEP PLS P Examples MOVP INCP etc SP GP ZP JP Intelligent Function Module Dedicated Instructions FF LEDR DUTY TRACE TRACER 3 Fall Instruction If signal flow memory has not been tracked after system switching the fall instruction is processed as explained below a Processing When the systems are switched the new contro...

Page 283: ...the first scan after system switching b When signal flow memory has been tracked Jumping is executed from the second scan or later after system switching Diagram 7 3 ON OFF Operation of SCJ Instruction When Signal Flow Has Been Tracked SCJ Instruction Point SCJ jump old control system ON OFF Jump Do not jump SCJ jump new control system Jump Do not jump Begin system switching System switching Syste...

Page 284: ...ch SM1518 has been set as its execution condition cannot be executed after system switching Create a program to be executed at the time of SM1518 shutdown using shutdown pulse operation contact as shown in the diagram below when startup execution instructions with SM1518 execution conditions are executed The instruction is executed at the second scan after system switching in order that the fall i...

Page 285: ... CPU module Since the new control system CPU module provides the old output to the network module after system switching the output from the network module may change 2 Not selectable since an intelligent function module cannot be mounted on the main base unit in the redundant system 3 For the COM instruction select the refresh item with the special relay Link refresh selection during COM instruct...

Page 286: ... Instruction 8 Dedicated instructions for intelligent function module mounted to extension base unit The dedicated instructions for the intelligent function module mounted to the extension base unit cannot be used If used a stop error OPERATION ERROR error code 4122 occurs Remark For the dedicated instructions for the intelligent function module refer to the manual for the intelligent function mod...

Page 287: ...make SM420 to SM424 usable in the new control system CPU module Example A program starting an SM420 timing clock 1 scan ON 3 scan OFF by executing the DUTY instruction in the new control system CPU module 1 This is the contact point for 1 scan ON in the new control system after SM1518 system switching If DUTY instructions are executed for SM1518 shutdown the DUTY instructions are executed on the s...

Page 288: ...T as shown in Diagram 7 8 The maximum value for the extension time is T when Diagram 7 8 Operations of Fixed Scan Execution Type Programs at System Switching Begin system switching System Switching complete T System switching time System switching activated Control system Control system New standby system New standby system New control system Standby system Standby system New control system Scan e...

Page 289: ...e new control system CPU module starts counting the interrupt interval time from 0 Therefore the fixed scan execution interval is increased T as shown in Diagram 7 9 The maximum value for the extension time is T when Diagram 7 9 Operations of Interrupts by Internal Timers at System Switching Begin system switching System Switching complete T System switching time System switching activated Control...

Page 290: ... control system CPU module does not execute the interrupt program of the interrupt factor accepted by the control system CPU module 2 When the Standby System CPU Module receives an interrupt The standby system CPU module holds the interrupt factor received from an intelligent function module When the standby system CPU module becomes the new control system CPU module through system switching it ex...

Page 291: ...d I31 execution via an internal timer are shown in Diagram 7 10 When execution of programs interrupted during tracking processing is not done execute DI instructions then execute EI instructions at step 0 before executing END instructions as shown in the program in the Diagram 7 11 As interrupt is disabled during END processing including tracking processing the CPU will not execute the interrupt p...

Page 292: ...w control system CPU module Table7 6 Operations of Control System and Standby System CPU Modules When F10 Is Turned ON in Control System CPU Module Item Control System CPU Module Standby System CPU Module F10 Annunciator ON ON SM62 Annunciator detection ON OFF SD62 Annunciator No The annunciator No turned on is stored No change SD63 No of annunciators Number of annunciators turned on is stored No ...

Page 293: ...SER LED off command M100 2 When turning on the annunciators in the new control system CPU module at system switching By turning on the annunciators in the new control system the USER LED can be turned on a When turning on the annunciators by the OUT instruction By tracking the OUT instruction execution condition the annunciators can also be turned on in the new control system CPU module at system ...

Page 294: ...he new control system CPU module at system switching 1 SM1518 is a contact that turns on in the new control at occurrence of system switching and remains ON for one scan Diagram 7 15 Program That Turns on the Annunciators by the SET Instruction after System Switching F10 is turned on at the second scan SM1518 ON OFF after system switching 1 F11 is turned on at the second scan SM1518 ON OFF after s...

Page 295: ...nce such as turning power supply OFF tracking transfer processing may be discontinued and the device data may not be reflected to the new control system CPU module after switching systems In this case the data output and the device data of the new control system CPU module may mismatch When the CPU module communicates with the intelligent function module or external device using the output Y and t...

Page 296: ... OFF X10 Y10 of CPU module External output of Y10 Standby system CPU module New control system CPU module Tracking transfer processing Tracking transfer processing Scan execution type program Scan execution type program Reflect tracking transfer data Prepare tracking transfer data Prepare tracking transfer data Error occurrence Reflect tracking transfer data Send Wait Wait Receive Send Receive Sen...

Page 297: ...or transferring conditions to the standby system CPU module from the control system CPU module Diagrams 7 18 and 7 19 show a program example which delays the output by one scan from the command output condition establishment a Input is returned corresponding to output Program example Before measures After measures Diagram 7 17 Program Example when there is Response Input to Output Response input X...

Page 298: ...he time of system switching occurrence 2 Depending on timing of system switching occurrence such as turning power supply OFF tracking transfer processing may be discontinued and the device data may not be reflected to the new control system CPU module after switching systems In this case the timer whose time is up before switching systems may not be recognized even after the first scan after syste...

Page 299: ... processing is completed after outputting the output Y from the timer contact is shown in Diagram 7 19 Program example Diagram 7 19 Chattering Occurs to Output by Timer Contact M0 T0 K10 T0 SET Y10 0 END END END 0 0 END 0 0 0 Control system CPU module Program OUT TO OUT TO OUT TO M0 ON ON ON ON OFF OFF ON ON OFF OFF OFF OFF Coil of T0 Contact of T0 Y10 of CPU module External output of Y10 Standby ...

Page 300: ...dundant parameter 3 Precautions regarding writing data from the GOT and external device etc Pay attention to the following points regarding writing data from the GOT and external device etc 1 The tracking data may not be reflected to the new control system CPU module depending on the timing of the system switching occurrence such as turning power supply OFF In this case data written immediately be...

Page 301: ...a module mounted on the extension base unit are GX Developer and PX Developer However there are restrictions on applicable functions For details refer to the following manuals GX Developer Version 8 Operating Manual PX Developer Version 1 Operating Manual Programming Tool 3 Tracking device setting When tracking device setting is not set the program is executed using the value before refresh is per...

Page 302: ...tes the CPU module operation status On The CPU is Running The RUN STOP switch RUN position Off The CPU has Stopped The RUN STOP switch STOP position The standby system CPU module in backup mode The RUN STOP switch RUN position An error that stops operation has been detected Flashing The RUN STOP switch is set to the STOP position to write parameters programs into CPU and then the switch is returne...

Page 303: ... standby system is being executed 8 CONTROL LED Indicates the system of the CPU module i e control system or standby system On Control system System switching is possible as the standby system is normal Debug mode Off Standby system 9 SYSTEM A LED Indicates the system A CPU module status On Operating as system A Debug mode Flashing The tracking cable has been disconnected while the CPU module is n...

Page 304: ...tching has occurred To the flow for when a system switching could not be performed The RUN LED does not light up A system switching has occurred To the flow for when the RUN LED does not light up The MODE LED does not light up The system switching could not be done Error Details To the flow for when the BACKUP LED is lit up solid red To the flow for when the SYSTEM A B LED is flashing The BACKUP L...

Page 305: ... Does the MODE LED light up NO Neutral position Replace the power supply module and confirm the POWER LED is lit Is communication with GX Developer possible Does the MODE LED light up Perform a PLC diagnostic and troubleshooting based on the diagnostic results Check the wiring and turn on the power QCPU User s Manual Hardware Design Maintenance and Inspection Is the CPU module s RESET L CLR Switch...

Page 306: ...standby system s power turned ON Has standby system s CPU module reset been canceled Is the BACKUP LED lit up solid green NO Cancel the standby system s CPU module reset Clearing control system CPU module errors Is the BACKUP LED lit up solid green YES YES Connect GX Developer to the standby system CPU module and check for faulty behavior using the System Monitor PLC diagnostics 2 Correct abnormal...

Page 307: ...ar the control system CPU module errors Is the BACKUP LED lit up solid green Replace standby system s CPU module Clear the control system CPU module errors Is the BACKUP LED lit up solid green YES 1 2 3 Replace the tracking cable YES NO Is the BACKUP LED lit green Power off the standby system Disconnect and then reconnect the tracking cable Power on the standby system Reset the error of the contro...

Page 308: ...le whose first 5 digits of serial No is 09012 or later refer to Sections 8 1 9 and 8 1 10 for the description of error detected by the standby system Diagram 8 4 Flow for the Case where the CPU Module BACKUP LED is ON Lit Red NO Clear the control system CPU module errors Please contact the nearest Mitsubishi represenative reseller or branch office and explain the fault symptoms Replace control sys...

Page 309: ... is flashing Power off the standby system Has the tracking cable been connected to the control system and standby system CPU modules NO Is the tracking cable connector secured to the CPU module with screws Is the SYSTEM A B LED lit Secure the tracking cable connector to the CPU module with screws Is the SYSTEM A B LED lit Disconnecting the tracking cable from the control system and standby system ...

Page 310: ... control system CPU module errors Please contact the nearest Mitsubishi represenative reseller or branch office and explain the fault symptoms Replace control system s CPU module Is the SYSTEM A B LED lit up solid green YES YES Is the SYSTEM A B LED lit up solid green 2 1 Completed YES NO Is the SYSTEM A B LED lit Replacing the tracking cable Completed Reset the errors of the control system and st...

Page 311: ...ROL LED CHAPTER 8 3 When the RUN LED of the standby system CPU module is flashing in the separate mode set the RUN STOP switch of the standby system CPU module from RUN to STOP to RUN 4 When using the CPU module whose first 5 digits of serial No is 09012 or later refer to Sections 8 1 9 and 8 1 10 for the description of error detected by the standby system after switching systems NO YES Backup mod...

Page 312: ...e failure Is the ERR LED ON or flashing NO NO Perform a remote RUN to set to RUN status Set to RUN status by turning off the RUN contact PAUSE contact YES YES Has a remote STOP PAUSE been done Is the RUN contact PAUSE contact ON Please contact the nearest Mitsubishi represenative reseller or branch office and explain the fault symptoms Connect GX Developer to the control system CPU module and chec...

Page 313: ...ching has occurred while the redundant system is running YES YES NO NO 1 Connect GX Developer to the control system CPU module and check the error log using the System Monitor PLC diagnostics Monitor the system switching cause using GX Developer PLC diagnostic error log and reviewing details for CONTROL EXE error code 6200 A system switching has not occurred Is switch factor 1 Turn ON the standby ...

Page 314: ... for system switching instruction arguments Correct abnormal behavior as appropriate for the argument Confirm with the GX Developer which performed the system switching Is switch factor 2 1 This is a hardware fault in the CPU module so please contact the nearest Mitsubishi represenative reseller or branch office and explain the fault symptoms Connect GX Developer to the standby system CPU module a...

Page 315: ...d while the redundant system was running 1 In the Case of System Switching by GX Developer Diagram 8 8 Flow for the Case where System Switching Has Failed Systems did not switch Resolve the fault based on error message content displayed in GX Developer Check if switching is possibly by requesting another system switching with GX Developer Check again following the troubleshooting flow for systems ...

Page 316: ...he standby system power NO Is the standby system s power turned ON YES Cancel the standby system s CPU module reset NO Has the standby system s CPU module reset been canceled Reconfirm the connection status of the tracking cable for both systems Reconnect YES NO For system A if a cable has been disconnected during normal operation the LED will flash until A system s connector is reconnected For sy...

Page 317: ...to confirm the problem area and resolve the problem Check operation starting from a minimum system and work your way up For modules that are not functioning contact the nearest Mitsubishi represenative reseller or branch office and explain the fault symptoms YES NO YES Green Backup mode Use GX Developer to change the running mode to backup mode NO Amber Separate mode Is the BACKUP LED ON solid gre...

Page 318: ... errors YES Depending on the control system error code confirm below and resolve the fault NO YES Specify a value other than 0 for SP CONTSW Turn ON SM1592 For separate mode operation Change the program to respond to SP CONTSW instructions not from the standby system but from the control system 3 4 4 4 2 Has an operation error occurred from the control system s system switching instruction Is SD16...

Page 319: ...oblems Check operation starting from a minimum system and work your way up For modules that are not functioning contact the nearest Mitsubishi represenative reseller or branch office and explain the fault symptoms Using GX Developer or a switching instruction reissue a system switching request and check that the system switches NO For the control system network module are there any faulty modules ...

Page 320: ...he procedures shown in Chapter 4 2 Corrective action for TRK INIT ERROR If TRK INIT ERROR has occurred during a startup of the redundant system restart the system by performing either of the following operations a Power on System A and System B again 1 When System A System B has been powered off power on System A and System B again simultaneously 2 The System A CPU module starts as a control syste...

Page 321: ...r system was powered off The CPU module in either system was reset and then its RESET switch was set to the neutral position 2 Corrective action for CONTROL SYS DOWN If CONTROL SYS DOWN has occurred during a startup of the redundant system restart the system by performing either of the following operations a Power on System A and System B again 1 Power on System A and System B again simultaneously...

Page 322: ...extension cable Turn OFF power supply of control system Connect OUT connector of main base unit of control system and IN1 IN2 connector by extension cable Are main base unit of standby system and Q65WRB connected by extension cable Turn OFF power supply of standby system Connect OUT connector of main base unit of control system and IN2 IN1 connector of Q65WRB by extension cable 1 Turn ON power sup...

Page 323: ...em NO NO NO YES YES YES Error message BASE LAY ERROR was detected Is error code 2010 Does the number of stages of extension base unit exceed specifications Change the number of stages of extension base unit according to specifications Check serial No of CPU module by system monitor of GX Developer Is first 5 digits of serial No of CPU module 09012 or later Replace CPU module with the one compatibl...

Page 324: ...tems A and B Is Q4 base connected Remove Q4 base and replace with redundant power extension base unit Is Q5 B extension base unit incompatible with power supply module connected Remove Q5 B and replace with redundant power extension base unit Check serial No of CPU module by system monitor of GX Developer Is first 5 digits of serial No of CPU module 09012 or later Replace with CPU module compatibl...

Page 325: ...e the same Are mode settings of systems A and B of network module the same Set the mode setting of system B the same as mode setting of system A in Redundant settings of network parameter Is error code 6035 Since the CPU model name differs between control system and standby system in redundant system use the same one Is error code 6036 Check to see if network cable is not broken since remote I O c...

Page 326: ...elevant slot mounted correctly and the extension cable of the relevant base unit connected correctly An error message SP UNIT DOWN was detected YES YES NO NO NO NO YES Is CC Link IE Controller Network module mounted YES Replace the CPU module with the one whose first 5 digits is 10042 or later Remove the relevant module Mount the module on the relevant slot correctly or connect the extension cable...

Page 327: ...ce the number of mounted MELSECNET H modules to four or less Are three or more CC Link IE Controller Network modules mounted Reduce the number of mounted CC Link IE Controller Network modules and MELSECNET H modules to four or less in total Are five or more CC Link IE Controller Network modules and MELSECNET H modules mounted in total Are five or more MELSECNET H modules mounted Reduce the number ...

Page 328: ...Are pairing settings made to the Redundant CPUs in the normal station Is the network type specified in network parameter same with the actual network type Check the network parameter and mounted status If they differ make them to the same Is the refresh parameter out of the range An error message LINK PARA ERROR was detected NO YES NO NO NO NO YES Is the network number specified in network paramet...

Page 329: ...mber Rewrite the network parameters Is MELSECNET H module a relevant module CC Link IE Controller Network module Does the refresh range exceed the file register capacity Are the station numbers with pairing settings serial numbers Are parameters of the PLC to PLC network no settings when the station number is 0 Are parameters of the remote master station no settings when the station number is othe...

Page 330: ...s detected NO NO YES YES Is CC Link IE Controller Network module of function version D used Is MELSECNET H module of function version D used YES Is Ethernet module of function version D used Use MELSECNET H module of function version D NO Use Ethernet module of function version D Use CC Link IE Controller Network module of function version D Check operation starting from a minimum system For modul...

Page 331: ...le of the control system may issue a switching request detecting a communication error due to turning power supply ON OFF of the other station including the standby system CPU module or booting and shutting down the personal computer where CC Link IE Controller Network interface board or MELSECNET H board is mounted For details of function requesting to switch system to the control system CPU modu...

Page 332: ...hen executing the error cancel command automatically change error cancel command M100 in Diagram 8 17 to be always ON SM400 3 Programming of CC Link IE Controller Network or MELSECNET H CC Link IE Controller Network or MELSECNET H network detects a temporary communication error depending on conditions such as power supply ON OFF or cable and noise Create the program using CC Link IE Controller Net...

Page 333: ... relevant special relay special register and LED return to the previous statuses If the same error occurs again after that it will be re registered in the failure history b Cautions 1 When the corresponding error code is stored in SD50 and error clear is performed the last digit of the code No will be ignored When multiple errors of which codes are different in the last digit only occur the errors...

Page 334: ...abled in the control system CPU module only If this method is executed in the standby system CPU module the standby system error will not be cleared The operation modes applicable to this error clear method are shown in Table8 2 Standby System Error Clear Enabled Standby System Error Clear Disabled Irrelevant as Standby System Does not Exist 2 When the corresponding error code is stored in SD1649 ...

Page 335: ...uction is executed with SM1649 ON c Sample Program for Clearing Standby System CPU Module Error The following shows a sample program for clearing the standby system error by the control system CPU module Sample Program A continuation error currently occurring in the standby system is cleared when the error clear command M100 turns ON Create the control system s program that enables the ON OFF stat...

Page 336: ...r occurrence even when error clear operation has been performed for the error which corresponds to the error code stored in special register SD0 SD1610 check the error history information in the online PLC diagnostics of GX Developer 1 Clear the latest errors and any errors that occurred simultaneously in the error history 1 When error clear operation is performed and the error is cleared the SD0 ...

Page 337: ... system can be powered off even while the redundant system is running 2 Replacement Procedure The procedure for replacing the CPU module is shown in Diagram 8 21 Diagram 8 19 System where Control System CPU Module is Replaced Diagram 8 20 System where Standby System CPU Module is Replaced Confirming the System of the Replacement Target CPU Module Confirm that system of the target CPU module is the...

Page 338: ...acking cable Power ON the Standby System 1 Set the RUN STOP switch of the standby system CPU module to the STOP position 2 Set the RESET L CLR switch of the standby system CPU module to the central position reset switch neutral position 3 Power on the standby system Confirming the POWER LED of the Power Supply Module Confirm that the POWER LED of the power supply module is ON lit green and the mod...

Page 339: ...nt operation Replace the power supply module for the standby system after turning the power supply for the standby system OFF The standby system power supply can be turned off even when the redundant system is active 1 When a pair of redundant power supply modules is used in each system one redundant power supply module can be replaced at a time while the redundant system is running Section 8 3 3 ...

Page 340: ...GX Developer Turn the Standby System Power Supply OFF Removing the wiring Disconnect the power supply cable from the standby system power supply module Replacing the Standby System Power Supply Module 1 Remove the power supply module from the main base unit 2 Mount the alternative power supply module to the main base unit Refer to the QCPU User s Manual Hardware Design Maintenance and Inspection f...

Page 341: ...supply modules is shown in the Diagram 8 25 Confirming the Replacement Target Power Supply Module Identify the faulty power supply module using the System Monitor of GX Developer Power OFF the Target Power Supply Module Removing the Wiring Disconnect the power supply cable from the target power supply module Replacing the Power Supply Module 1 Remove the power supply module from the main base unit...

Page 342: ...hile the redundant system is running regardless of its system i e control system or standby system POINT The I O modules of control system and standby system cannot perform online module change hot swapping using GX Developer when connecting the extension base unit to the CPU module whose first 5 digits of serial No is 09012 or later When replacing modules online using GX Developer in other than a...

Page 343: ...fer to Section 5 2 for system switching using GX Developer Turn the Standby System s Power Supply OFF Removing the Terminal Block Connector from the I O module Remove the terminal block connector from the I O module Replace the Standby System s I O Unit 1 Disconnect the I O module from the main base unit 2 Mount an alternative I O module the same model as the control system I O module to the main ...

Page 344: ...etwork modules is indicated in Diagram 8 31 Diagram 8 29 System where Control System Network Module Is Replaced Diagram 8 30 System where Standby System Network Module Is Replaced Confirm the Network Module Targeted for Replacement Confirm that the CPU module of the system to be replaced is the standby system CONTROL LED is off When replacing the network module of the control system make it the st...

Page 345: ...le 1 Disconnect the network module from the main base unit 2 Attach the replacement network module a network module of the same type as the control system network module For removal and installation of the network module refer to the manual of the used network module Wiring Connect the network cable to the network module Refer to the manual of the network module for connecting the network cable Tu...

Page 346: ...tandby system s main base unit after turning the standby system s power supply OFF The power supply for the standby system can be turned OFF even when the redundant system is active Diagram 8 32 System where Control System s Main Base Unit Is Replaced Diagram 8 33 System where Standby System s Main Base Unit Is Replaced Control system Standby system Tracking cable Replace after using GX Developer ...

Page 347: ... to the manual of the network module for disconnecting the network cable 4 Remove the connector terminal block from the I O module 5 Disconnect the extension cable for mounting the main base unit of the standby system Removing Modules Remove the modules from the main base unit Refer to the QCPU User s Manual Hardware Design Maintenance and Inspection for removing modules Replacing the Main Base Un...

Page 348: ...y Refer to Section 8 2 for the error resetting method Turn on the Standby System s Power Supply 1 Align the position of the standby system CPU module s RUN STOP switch with that of the control system 2 Set that standby system CPU module s RESET L CLR switch to the central position reset switch neutral position 3 Turn the standby system s power supply ON Confirm the Power Supply Module s POWER LED ...

Page 349: ... station can be replaced while the redundant system is running Following modules can be replaced by using this method I O Module 1 Intelligent Function Module 2 Analog module temperature input module temperature control module pulse input module 1 Refer to the following manual for module replacement by using online module change of GX Developer Q Corresponding MELSECNET H Network System Reference ...

Page 350: ...manual QCPU User s Manual Hardware Design Maintenance and Inspection 2 For changing modules online hot swapping using GX Developer refer to the manual for the intelligent function module used POINT 1 When connecting the extension base unit use the Redundant CPU whose first 5 digits of serial No is 09012 or later in both systems In addition connect the redundant type extension base unit to the firs...

Page 351: ...lacement 1 Tracking Cable Replacement The tacking cable cannot be replaced while both systems are running After powering off the standby system or keeping the standby system CPU module reset replace the tracking cable The standby system can be powered off or reset while the redundant system is running Diagram 8 35 System where Tracking Cable Replacement Control system Standby system Replace the tr...

Page 352: ...t Tacking Cable Replacement 1 Disconnect the tracking cable from the control system CPU module Refer to Section 3 3 for disconnecting the tracking cable 2 Disconnect the tracking cable from the standby system CPU module 3 Connect the tracking cable connector to the standby system CPU module Refer to Section 3 3 for disconnecting the tracking cable 4 Connect the tracking cable connector to the cont...

Page 353: ...ere the extension cable to be replaced is connected Check that the extension cable to be replaced is connected to the standby system CONTROL LED is turned OFF When connecting an extension cable of the control system switch system to the standby system by GX Developer Turning OFF power supply of standby system Replacement of an extension cable of the standby system Disconnect an extension cable fro...

Page 354: ...and instruction execution added to the tracking time for END processing Refer to the following manual regarding I O refresh instruction execution time and END processing for control CPU module redundant CPUs QCPU User s Manual Function Explanation and Program Fundamentals The method for adding tracking time is explained here The time required for system switching will also be explained ...

Page 355: ... Processing Time Tp Program Execution Time Overhead time for tracking transfer according to the right table Condition ms Both systems are normal Max 4 When a momentary power failure or power off occurs in the standby system Momentary power failure time to max 40 While communication is executed via tracking cable Max 30 Control system Standby system Extension of Scam Time Sequence Sequence Adjust T...

Page 356: ... X3 Processing time according to number of tracking blocks for tracking settings X3 F1 K9 F2 K10 F3 K11 ms D1 to D4 E1 to E4 F1 to F3 and K1 to K11 are values used in Table9 3 Tra 1 Tra1 Tra2 Tra3 Tra4 ms Tra Tracking Data Preparation Time Tra1 to Tra4 Transfer Data Processing Time Shown in Table9 2 Table9 2 Processing Times of Tra1 to Tra4 Transfer Data Processing Time ms Tra1 Signal Flow Memory ...

Page 357: ...9 3 Counting Value of D1 to D4 E1 to E4 F1 to F3 and K1 to K11 Symbol Content System Number Symbol Counting Value D1 Number of Tracking Device Points outside of Index Register K1 0 09 10 3 D2 Number of Tracking Device Points for Index Register K2 0 15 10 3 D3 Number of Tracking Device Points for Standard RAM File Register K3 0 09 10 3 D4 Number of Tracking Device Points for SRAM Card File Register...

Page 358: ...able9 4 Number of N1 to N4 Data Transferred Transfer Data Number of Data Transferred Words N1 Signal flow Memory Time set for redundant parameter tracking settings Number of steps for each program 16 1 N2 SFC Information SFC program execution time 13312 13k Fixed N3 PID Control Instruction Information PIDINIT Instruction Execution Time 1024 1k Fixed S PIDINIT Instruction Execution Time 1024 1k Fix...

Page 359: ...tion time for tracking data using the standby system CPU module T m CC Link IE Controller Network MELSECNET H CC Link PROFIBUS DP automatic refresh time T m Refer to the manual for the network module being used When the extension base unit is connected Signal flow memory is not tracking transferred 31 5ms Signal flow memory is tracking transferred 12 5ms When the extension base unit is not connect...

Page 360: ...g time according to number of tracking blocks for tracking settings X3 F1 K9 F2 K10 F3 K11 ms D1 to D4 E1 to E4 F1 to F3 and K1 to K11 are values used in Table9 6 Trc 1 Trc1 Trc2 Trc3 Trc4 ms Trc Trc1 to Trc4 Tracking data preparation time Processing time for transfer data shown in Table9 5 Table9 5 Processing Times of Tra1 to Tra4 Transfer Data Processing Time ms Trc1 Signal Flow Memory Setting t...

Page 361: ...ting Value of D1 to D4 E1 to E4 F1 to F3 and K1 to K11 Symbol Content System Number Symbol Counting Value D1 Number of Tracking Device Points outside of Index Register K1 0 09 10 3 D2 Number of Tracking Device Points for Index Register K2 0 15 10 3 D3 Number of Tracking Device Points for Standard RAM File Register K3 0 09 10 3 D4 Number of Tracking Device Points for SRAM Card File Register K4 0 42...

Page 362: ... Program Priority Mode 21 ms 1 Repeat Mode 34 2 ms 1 System Switching Time Tsw 21 T Trc Refer to Section 9 2 300ms System Configuration A Series Modules N A Applicable QnA Series Modules N A Applicable CC Link Auto Refresh Setting Applicable Maximum 4 Modules N A Performed using FROM TO instruction Maximum Number of Modules Mounted on Main Extension Base Unit First 5 digits of serial No is 09011 o...

Page 363: ... modules cannot be mounted to remote I O stations CC Link IE Controller Network module MELSECNET H module interrupt module Web server module MES interface module PROFIBUS DP master module PROFIBUS DP slave module PROFIBUS DP interface module DeviceNet master module DeviceNet slave module and AS i master module For Ethernet modules dedicated instructions interrupt pointers e mail function communica...

Page 364: ...r Enabled 16 character LED display auto diagnostics information and comments are displayed N A Auto diagnostics error information and comments etc can be confirmed using GX Developer Available Manual System Switching System switching by the system switching instructions or redundant operation of GX Developer System switching using switches of bus switching module A6RAF Manual operational mode swit...

Page 365: ...Function Status Latch N A Applicable Program Trace N A Applicable Simulation N A Substituted with GX Simulator Applicable Step Execution Sequence Program N A Substituted with GX Simulator Applicable SFC Program N A Table App 2 Instructions Inapplicable for QnPRHCPU Instruction symbol Instruction Name Instruction symbol Instruction Name LED LED Display of ASCII code PR Print ASCII code LEDC LED dis...

Page 366: ...zed tracking mode 41 ms Program priority mode 21 ms System Configuration A Series Module N A Applicable Maximum Number of Modules Mounted on Main Extension Base Unit First 5 digits of serial No is 09011 or earlier 11 modules Main base unit only Modules which are not duplicated are mounted to MELECNET H remote I O station Number of mountable modules on remote I O station 64 modules per station Firs...

Page 367: ...s cannot be mounted to remote I O stations CC Link IE Controller Network module MELSECNET H network module interrupt module Web server module MES interface module PROFIBUS DP master module PROFIBUS DP slave module PROFIBUS DP interface module DeviceNet master module DeviceNet slave module and AS i master module For Ethernet interface modules dedicated instructions interrupt pointers e mail functio...

Page 368: ...onnection Applicable N A for extension base unit Applicable Mounting I O module or network module on slot 0 Disabled Slot 1 becomes I O number 0 Mount I O modules and network modules on slots 1 and later Enabled Restriction on the applicable intelligent function modules Applied The Ethernet modules and MELSECNET H modules of serial No 06052 or later are applicable Not applied Programming Tool GX D...

Page 369: ...rtup UDCNT1 1 phase Input Up Down Counter D P CHGV Axis Speed Change during Positioning and JOG operation UDCNT2 2 phase Input Up Down Counter D P CHGT Torque Control Value Change during Operation and Suspension in Real Mode TTMR Teaching Timer D P CHGA Current value Change of Halted Axis Synchronized Encoder Cam axis STMR Special Timer D P DDWR Write Other CPU Device Data into Host CPU ROTC Rotar...

Page 370: ... time Synchronized tracking mode 41 ms Program priority mode 21 ms System Configuration Maximum Number of Modules Mounted on Main Extension Base Unit First 5 digits of serial No is 09011 or earlier 11 modules Main base unit only Modules which are not duplicated are mounted to MELECNET H remote I O station Number of mountable modules on remote I O station 64 modules per station First 5 digits of se...

Page 371: ...wing modules cannot be mounted to remote I O stations CC Link IE Controller Network module MELSECNET H module interrupt module Web server module MES interface module PROFIBUS DP master module PROFIBUS DP slave module PROFIBUS DP interface module DeviceNet master module DeviceNet slave module and AS i master module For Ethernet modules dedicated instructions interrupt pointers e mail function commu...

Page 372: ...n Applicable N A for extension base unit Applicable CC Link Connection Applicable Applicable MELSECNET H Remote I O Station Connection Applicable N A for extension base unit Applicable Mounting I O module or network module on slot 0 Disabled Slot 1 becomes I O number 0 Mount I O modules and network modules on slots 1 and later Enabled Restriction on the applicable intelligent function modules Appl...

Page 373: ...rtup UDCNT1 1 phase Input Up Down Counter D P CHGV Axis Speed Change during Positioning and JOG operation UDCNT2 2 phase Input Up Down Counter D P CHGT Torque Control Value Change during Operation and Suspension in Real Mode TTMR Teaching Timer D P CHGA Current value Change of Halted Axis Synchronized Encoder Cam axis STMR Special Timer D P DDWR Write Host CPU Device Data into Other CPU devices RO...

Page 374: ... sample program device Nos and for CC Link network parameters Appendix 4 2 Sample Program Names The sample program names are shown in Table App 9 Change the program names to match the system used When changing the program name the program name should also be changed in the program settings of the PLC parameter settings Diagram App 1 Sample Program System Configuration Table App 9 Sample Program Na...

Page 375: ...truction error flag OFF normal ON error M4531 During data link execution OFF Not executed data link ON During data link execution D100 D107 Interrupt enable or interrupt disable IMASK instruction 0 interrupt prohibited 1 interrupt enabled SD1601 System switching condition 16 system switching instruction SD1602 System switching instruction argument Argument specified by SP CONTSW instructions I41 P...

Page 376: ... transfer range on the CC Link side and the device range on the CPU side to match them with the number of stations and module types on the system used 1 Indicates the number of transferred data that is specified in the BMOV instruction Table App 12 Refresh Devices CC Link Side CPU Side Device Name Transfer Range Buffer Memory Head Address Number of Data Transferred Words 1 Device Used Remote Input...

Page 377: ...TEMS APPENDICES INDEX Appendix 4 4 Parameter Settings The PLC parameters and network parameters for using the sample program are shown here 1 Program Settings The program settings of the PLC parameter settings are shown in Diagram App 2 Set MAIN as a number lower than CHANGE in program settings Diagram App 2 Program Setting Screen ...

Page 378: ... 4 4 Parameter Settings APPENDICES 2 Tracking Settings Make the settings so that the remote output Y1000 to Y109F and remote register W1100 to W1113 will be tracked in the tracking settings of the redundant parameter settings Diagram App 3 Tracking Setting Screen ...

Page 379: ...The content of CC Link Network Parameter Settings The content of network parameter settings is shown below 1 Module Count Set module count to 1 in network parameter settings 2 Starting I O Number Set the master station s starting I O number to 40 3 Type Confirm that the station type is Master Station Duplex function 4 Mode Set CC Link s mode as Remote Network Ver 1 Mode 5 All Connect Count Set the...

Page 380: ... Use 1 link scan for return to system set at 1 Default 10 Standby Master Station No Set the standby master station number to station number 5 11 PLC Down Select Use the data link status as Stop Default for when CPU errors occur in the master station sequence 12 Scan Mode Setting Use the setting for link scan for sequence scan as Asynchronous Default 13 Delay Information Setting Use the link scan i...

Page 381: ...its is 07112 or later a Sample Program Name CHANGE 1 Sample program overview flow Diagram App 6 Sample program overview flow Set I41 to be valid Step 0 to 11 Refresh the remote devices and enable system switching Step 15 to 35 Initialize devices at the time of system switching Step 12 to 14 Refresh the CC Link Step 36 to 45 CHANGE FEND Forcibly change the system that communicates with the CC Link ...

Page 382: ... Y1000 to Y109F Performs a refresh of RX X1000 to X109F Performs a refresh of RWw W1100 to W1113 Performs a refresh of RWr W1000 to W1013 Set refresh update request signal to ON Set refresh update request signal to OFF Set control program execution flag to ON End main routine program Set CC Link forced master switching flag to ON Set control program execution flag to OFF End interrupt program Set ...

Page 383: ...w flow 2 Sample program Diagram App 8 Sample program overview flow Diagram App 9 A sample program of MAIN Turn the enable control program execution flag ON Step 0 to 1 Control the CC Link Step 2 to 18 MAIN END Set enable control program execute flag to ON When CC Link is operating as master station and data link is properly executed set M4531 to ON Control CC Link Creates the CC Link control progr...

Page 384: ...agram App 10 Sample program overview flow Set I41 to be valid Step 0 to 11 Refresh the remote devices and enable system switching Step 17 to 38 Initialize devices at the time of system switching Step 12 to 16 Refresh the CC Link Step 39 to 55 Perform system switching when system B starts up as the control system Step 56 to 69 CHANGE FEND Forcibly change the system that communicates with the CC Lin...

Page 385: ...system switching by SP CONTSW Set CC Link forced master switching flag to OFF Set system switching execution flag to ON Set System B first startup system switching flag to OFF Set refresh update request signal to ON Set refresh update request signal to OFF Set control program execute flag to ON Switches the system when System B has started first Set System B first startup system change flag to ON ...

Page 386: ...m App 12 Sample program overview flow Diagram App 13 A sample program of MAIN Turn the enable control program execution flag ON Step 0 to 1 Control the CC Link Step 2 to 18 MAIN END Set enable control program execute flag to ON When CC Link is operating as master station and data link is properly executed set M4531 to ON Control CC Link Creates the CC Link control program ...

Page 387: ...i e system B as the control system in this condition create the following program Diagram App 14 that uses the special relay Previous control system identification flag SM1519 However when mounting a network module on the main base unit or extension base unit create an interlock circuit as shown on the programs in Diagram App 20 and Diagram App 22 before executing the SP CONTSW instruction If batt...

Page 388: ...hing System B to the control system through a system switching instruction Diagram App 16 The system when power supplies of both systems are temporarily OFF Diagram App 17 The system when both systems are simultaneously powered ON Diagram App 18 The system when System B is switched to the control system through a system switching instruction Power ON OFF System A Power ON OFF System B Tracking cab...

Page 389: ...lowing points Turn on the special relay Manual System Switching Enabled Flag SM1592 by executing SP CONTSW instruction An OPERATION ERROR error code 4120 will occur if the SP CONTSW instruction is executed while SM1592 is OFF Set any value other than 0 as the parameter for SP CONTSW instruction If the SP CONTSW instruction is executed with the parameter set as 0 the OPERATION ERROR error code 4100...

Page 390: ...0 execute when the previous control system is the system B Executes the system switching instruction when the network module in the B system starts normally Jumps the processing to P101 with the system switching instruction Jumps the processing to the END instruction by executing the system switching instruction Enables communications with GX Developer or others Calculates the subroutine program e...

Page 391: ...B Executes the system switching instruction when the CC Link master module on extension base unit starts normally X101 Interlock signal Jumps the processing to P101 with the system switching instruction Jumps the processing to the END instruction by executing the system switching instruction Enables communications with GX Developer or others Calculates the subroutine program executing time Program...

Page 392: ... the main base unit system B cannot start as the control system 3 If all stations are faulty in CC Link network system A system will be control system since Xn1 does not turn ON To start with the previous control system power ON the programmable controller CPU after powering ON the CC Link remote I O stations 4 To use the Rise Fall execution instruction in a program of B system after system switch...

Page 393: ...nd receive area size Applicable Appendix 6 1 Performs PLC CPU monitoring registration PLC monitoring cancel to use the PLC CPU monitoring function N A Clears receive data without stopping the send processing in the nonprocedural protocol Applicable Appendix 6 1 UINI Switches mode transmission specifications and host station number Applicable 1 Appendix 6 2 BUFRCVS Receives data in the interrupt pr...

Page 394: ...when the ready signal X n 1 E of a module is ON The program example of send receive data length unit setting is shown in Diagram App 23 For the I O signal is X Y80 to X Y9F b Specification of buffer memory head address and buffer memory size used in on demand function For the specification refer to Appendix 6 6 Table App 14 List of I O Signal I O signal Signal name Description of signal CH1 side C...

Page 395: ...th the function to be used On demand function of MC protocol Send receive function of nonprocedural protocol Send receive function of bidirectional protocol Table App 16 List of I O Signal I O signal Signal name Description CH1 side CH2 side X n 1 E Q series C24 ready ON Accessible X n 1 F Watchdog timer error WDT error ON Module error occurred OFF Module being normally operated Table App 17 List ...

Page 396: ...g the receive area head address and the receive area size is shown in Diagram App 25 For the I O signal is X Y80 to X Y9F Diagram App 24 Program Example Diagram App 25 Program Example Sets D0 to head address C00H Sets D1 to buffer memory length 100H Writes send area setting value 0 X9E X9F MOVP H0C00 D0 MOVP H100 D1 TOP H8 H0A2 D0 K2 Sets D0 to head address D00H Sets D1 to buffer memory length 300...

Page 397: ...on is discontinued when clear request is performed to the receive data Table App 18 Device Used in the Program Device No Application Remarks X23 Receive data clear request command ON Receive data clear request M11 Receive processing ON Executing OFF Not executed M12 Send processing ON Executing OFF Not executed M15 Receive data clear request pulse ON Receive data clear request M16 Receive data cle...

Page 398: ...nicate data when M19 is ON Diagram App 26 Program Example 0 PLS M15 3 M15 SET M16 SET M17 5 M16 M17 TO H8 H0A8 K1 K1 M18 1 1 X83 X84 1 RST M16 RST M17 RST M18 SET M18 T100 K10 H D0 K0 18 M17 T100 FROM H8 H0A8 D0 K1 30 M18 M19 37 M16 M17 M18 X23 M11 M12 2 Accepts the receive data clear request Requests the receive data clear Turns ON the receive data clear completion flag Reads the receive data cle...

Page 399: ...Mode switching Yn2 Yn9 Mode switching request Table App 23 List of I O Signal I O signal Signal name Description CH1 side CH2 side Xn3 XnA Reception data read request ON Requesting read Xn4 XnB Reception abnormal detection ON Abnormal detection XnE CH1 ERR occurrence ON Error occurring XnF CH2 ERR occurrence ON Error occurring X n 1 E Q series C24 ready ON Accessible X n 1 F Watchdog timer error W...

Page 400: ...hen connecting an external device to either interface CH1 or CH2 the communication speed can be set up to 115200bps 230400bps for the CH1 side of the QJ71C24N R2 R4 In this case the communication speed of the interface where the external device is not connected should be 300bps Set 00H to the interface side where GX Developer connection is set in the communication protocol setting The serial commu...

Page 401: ...annot be made Diagram App 27 Program Example Changes operation mode into MC protocol format 1 Sets transmission specification Writes mode switching specification contents to buffer memory Sets mode switching request Resets mode switching request signal Reads error description after switching mode Completes mode switching Resets mode switching completion Clears mode switching request by clear reque...

Page 402: ...or ON Module error occurred OFF Module being normally operated Yn1 Yn8 Reception data read completion ON Data read completed Table App 26 List of Buffer Memory Buffer memory address Hexadecimal decimal Name Stored value CH1 side CH2 side 258H 600 268H 616 Data reception result 0 Normal completion 1 or more Abnormal completion error code 600H 1536 A00H 2560 Receive data count Number of data for whi...

Page 403: ...l I O signal Signal name Description CH1 side CH2 side X n 1 8 Flash ROM write completion ON Completed Y n 1 8 Flash ROM write request ON Requesting Table App 29 List of Buffer Memory Buffer memory address Hexadecimal decimal Name Stored value CH1 side CH2 side 2H 2 Register read delete instructions 0 No request 1 Registration request 2 Read request 3 Deletion request 3H 3 Frame No direction 0 No ...

Page 404: ...egistered Sets registered data of a frame to be registered to D4 to D8 Registers user registration frame Reads registration result when write completion is turned ON Executes error processing when D2 is other than 0 0 PLS M50 3 MOV D0 K1 MOV D1 H3E8 MOV D3 K10 MOV D4 H3946 MOV D5 H3030 MOV D6 H3030 MOV D7 H4646 MOV D8 H3030 TO H8 H2000 K1 K1 TO H8 H2 K2 D0 TO H8 H5 K6 D3 FROM H8 H4 K1 D2 SET M1 RS...

Page 405: ...2 side X n 1 7 Flash ROM read completion ON Completed Y n 1 7 Flash ROM read request ON Requesting X n 1 E Q series C24 ready ON Accessible X n 1 F Watchdog timer error WDT error ON Module error occurred OFF Module being normally operated Table App 32 List of Buffer Memory Buffer memory address Hexadecimal decimal Name Stored value CH1 side CH2 side 2H 2 Register read delete instructions 0 No requ...

Page 406: ...ad command etc Sets read flag Turns ON the read request signal Reads result of read if read completion signal is turned ON Turns OFF the read request signal Reads the number of user registration frames Reads the user registration frame Resets the read flag 0 M1 PLS M0 SET M1 17 X97 M1 SET Y97 RST Y97 RST M1 X9F X9E TO H8 H2 D0 K2 X97 FROM H8 H4 D2 K1 FROM D2 K0 H8 H5 D3 K1 FROM H8 H6 D4 K0Z0 D3 K2...

Page 407: ...l completion ON Normal completion Xn1 Xn8 Transmission abnormal completion ON Abnormal completion Xn2 Xn9 Transmission processing Transmission in progress XnE XnF ERR occurrence ON Error occurring X n 1 E Q series C24 ready ON Accessible X n 1 F Watchdog timer error WDT error ON Module error occurred OFF Module being normally operated Yn0 Yn7 Transmission request ON Requesting transmission Table A...

Page 408: ...r Q series C24 N Writing is not required when send data is set in units of bytes words Pulse outputs send command Sets send data Sets the buffer memory head address where the send data is stored and the data length Program MOV K2 D3 when send data is set in units of words Resets output signal for checking operator Completed normally Failed Reads LED status and on demand execution result and checks...

Page 409: ... Xn7 Transmission normal completion ON Normal completion Xn1 Xn8 Transmission abnormal completion ON Abnormal completion Xn2 Xn9 Transmission processing Transmission in progress XnE XnF ERR occurrence ON Error occurring X n 1 E Q series C24 ready ON Accessible X n 1 F Watchdog timer error WDT error ON Module error occurred OFF Module being normally operated Yn0 Yn7 Transmission request ON Requesti...

Page 410: ...nd data and number of send data Writes the number of send data and send data to buffer memory Turns ON send request signal Y80 after writing data Turns OFF send request signal Reads send error code Turns OFF send request signal Take corrective action to the error according to error code stored in D20 Turns LED OFF and clears error code 0 23 X9E X80 X9F X80 X81 Y80 MOV abcdefg D11 MOVP H0A0D D15 MO...

Page 411: ...rence ON Error occurring X n 1 E Q series C24 ready ON Accessible X n 1 F Watchdog timer error WDT error ON Module error occurred OFF Module being normally operated Yn0 Yn7 Transmission request ON Requesting transmission Table App 41 List of Buffer Memory Buffer memory address Hexadecimal decimal Name Stored value CH1 side CH2 side B7H 183 157H 343 For user frame being transmitted designation CR L...

Page 412: ...ecification to output frame No specification to the schedule specification area Sets the number of send data Turns ON the send request signal Turns OFF the send request signal if the send completion signal is turned ON Reads the error code and turns OFF the send request signal if the send error complete signal is turned ON 0 42 PLS M50 SET Y80 MOV K4 D0 3 MOV H1234 D1 MOV H56AB D2 MOV H0 D10 MOV H...

Page 413: ... Xn7 Transmission normal completion ON Normal completion Xn1 Xn8 Transmission abnormal completion ON Abnormal completion Xn2 Xn9 Transmission processing Transmission in progress XnE XnF ERR occurrence ON Error occurring X n 1 E Q series C24 ready ON Accessible X n 1 F Watchdog timer error WDT error ON Module error occurred OFF Module being normally operated Yn0 Yn7 Transmission request ON Requesti...

Page 414: ...data Writes the send data and the number of send data to the buffer memory Turns ON the send request signal Y80 after the data is written Turns OFF the send request signal Reads the send error code Check the error description and take corrective action according to the error code stored in D20 Turns OFF the LED and clears the error code Turns OFF the send request signal 0 23 X9E X80 X9F X80 X81 Y8...

Page 415: ...error ON Module error occurred OFF Module being normally operated Yn1 Yn8 Reception data read completion ON Data read completed Table App 47 List of Buffer Memory Buffer memory address Hexadecimal decimal Name Stored value CH1 side CH2 side 258H 600 268H 616 Data reception result 0 Normal completion 1 or more Abnormal completion error code 600H 1536 A00H 2560 Receive data count Number of data for ...

Page 416: ...EC Communication Protocol Reference Manual Table App 48 Applicability of connection destination specification of each command from request source Function Connection destination specification Target Command name Control system Standby system No system specification System A System B Device memory Batch read Batch write Random read Test Random write Monitor data registration Monitor Multiple block ...

Page 417: ...PENDICES INDEX 3 System switching during communication made via a module on an extension base unit If system switching occurs during communication made via a module on an extension base unit by MC protocol or a dedicated instruction both the old and new control systems may not be able to respond and this may cause a communication timeout ...

Page 418: ...ectors 4 9 Consistency check 5 16 Basic system configuration consistency check 5 21 File consistency check 5 18 Memory card setting status consistency check 5 23 Operating status consistency check settings 5 20 Operation status consistency check 5 19 Parameter valid drive settings consistency check 5 25 Consistency check execution conditions 5 17 Consistency check points 5 16 CONTENTS 1 11 CONTROL...

Page 419: ... cautions 7 1 R Reason for system switching 5 34 Redundant CPU operation upon an error detection 5 26 Redundant power extension base unit 1 21 Redundant power main base unit 1 21 Redundant system functions 5 1 5 32 System switching method 5 33 Redundant system overview 1 4 Redundant system configuration 1 4 Redundant type extension base unit 1 21 Remote I O network 6 17 Remote latch clear 5 131 Re...

Page 420: ...ystem switching instruction 5 39 System switching condition 5 54 System switching dedicated command parameter 5 55 System switching disenabling condition 5 54 System switching during online program change 5 105 System switching execution possibility 5 44 5 49 System switching execution timing 5 43 System switching function 5 33 System switching method 5 33 System switching precautions 5 56 System ...

Page 421: ...e been avoided if functions or structures judged as necessary in the legal safety measures the user s device is subject to or as necessary by industry standards had been provided 4 Failure that could have been avoided if consumable parts battery backlight fuse etc designated in the instruction manual had been correctly serviced or replaced 5 Failure caused by external irresistible forces such as f...

Page 422: ...ted States and other countries Pentium is a trademark of Intel Corporation in the United States and other countries Ethernet is a trademark of Xerox Corporation All other company names and product names used in this manual are trademarks or registered trademarks of their respective companies SH NA 080486ENG O ...

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