Home

QnPRHCPU User`s Manual (Redundant System)

1. b Memory Copy Operations Diagram 5 88 illustrates the processes that take place in memory copy a Memory copy preparation Perform memory copy 3 Control system Standby system Control system Standby system 3 a 2 i a e a By E E a E E AL ELE 3 z Tracking cable Tracking cable T 20 wir 1 Be sure that SM1596 28 SM1597 are OFF and 2 Turn ON SM1595 ad store 3D1H in SD1595 3 Begin memory copy Display devices Display devices SM1596 ON E a q O o Z Memory copy complete 6 H Control system Standby system fz fao a e al al E a i fe e E cn Je il 2a z Slo u 5 Tracking cable aga BES ofa 4 Memory copy completed SM1596 0FF SM1597 ON SD1596 Status information Ol Display devices Diagram 5 88 Operation When Memory Copy Is Executed c Memory Copy special relay and special register status Executing memory copy Completed ON l o W 12 gt no E Zz lt x a Zz gt Q W a 7
2. 6 2 6 PROFIBUS DP 1 Communication overview of the PROFIBUS DP a In redundant system when the PROFIBUS DP master module detects a fault or w 3 i x N communication failure with DP Slaves the standby system master module is switched to new control system master module and inherits the PROFIBUS communications 2 Operation at system switching 7 E The PROFIBUS DP master modules switch each system on the following cases e When the PROFIBUS DP master module detects a fault Ba 7 i lt n e When a communication failure with DP Slaves is detected as Station No 0 Ta Control system Standby system l ANG 3 Oo An error has Z been detected fe Bus terminator Tracking cabie Bus terminator ci e H 5 EE S25 esieeles selec se oe a 0 DP Slave DP Slave lt b ti ji n a Control r Standby z9 system Station No 0 system Station No 1 5 6 ag ion No 1 ion No az New standby gtationNo New control Stalon No O Fe Te system system 6 g i Aei a W i U E 40 I S H i o y H l Contin
3. b Changing From Separate Mode to Backup Mode 1 Connect GX Developer to the control system CPU module w 2 Select Online Redundant operation from the menu bar of GX Developer to a open the Redundant operation screen 3 3 Open the GX Developer online Redundancy Procedure window Check the Change operation mode at the redundant operation area than select Backup mode from the list Z g E 4 Click on the Execute button zo Run in separate mode F BACKUP ON amber BACKUP E ON amber Se Control system Standby system e BI BeN al g g o kl H x al 2 5 a G G C B 9 Tracking cable fe fedusdanl operation Connector taigi inioma on backup mode Coreerdion tieiace COMI AC made change operation Jat LC Stank Hot Peye OA GX Developer Change to backup mode ci AC Ha as mode 52 Sysien hpr Coran aystem persion mode Sepaste wade T a 2 Ramon apasa M stiut z Z mips rey ami 29 Pa Run in backup mode OFS Change comaton node Sanne Q lt Q C Mame cosy BACKUP ON green BACKUP
4. Ay gl gl amp 1 A EFATE all z 8 e a line HR g E Se e i Tracking cable I I n Remote I O module pZ MELSECNET H Remote I O network D Serial communication j 7ST i module I ot T_ Remote O station Remote O station 1 i j S B E I sais f t When specifying System switching TE control system using activated MC protocol Multiplexed Remote Sub master Station _ Multiplexed Remote Master Station Control system E Standby system oom oo0000 o00000 E Tracking cable MELSECNET H Remote I O network Col 16S Remote I O module Serial communication 1 module Remote O station Remote O station i
5. 4 Network Module Station No Settings Set station No 0 multiplexed remote master station for the network module which is z mounted on system A a r gt Set any of station No 1 to 64 for the network module that is mounted on system B 2 If the network module mounted on system B is set to station No 0 the LINK PARA ERROR error code 3101 stop error will occur aang ties mete Multiplexed Remote Sub master Station 6 set to station No 0 set to any station No between 1 64 System A System B Ba 26 JES nO 8 N w Tracking cable a 3 S MELSECNET H Remote I O network x lt Diagram 6 16 Network Module Station No Settings E 5 Network Parameter Settings In the network parameters for system A and system B set the network type identically P lt x A as MNET H multiplexed remote master IEE 298 OH Ethernet card BEE ORS T oa ToT Module 1 Module 2 Module 3 Network type one None v None X Select MNET H Starting 1 0 No one oe a elec s NeWorNs MNET H mode Nome eaten Multiplexed remote master Total stations MNET 10 mode Control station Oo Group Na MNET HiMulpleved remote master g Station No o Mode X X X
6. QE Control system system E 3 ghi S elle E a al fF al BH E ira 2 3 ali pel a U gi sill o z Seals z e Sle Wir e J GE 1 Set online module Tracking cable ao change hot swapping 3 Cancel online module 2 Online module change hot swapping change hot swapping Replacement m module 2 O oO ae A O lt fe 1 to 3 shows the online module GX Developer change procedure Diagram 1 11 Online Module Change Hot Swapping of I O Modules mounted on a Main Base Unit a e b ME 10 System status can be monitored uge SO A AZA The operation status of the whole redundant system can be monitored using the ne z oc F Oza System Monitor of GX Developer cru Control system Standby system ale A al ale a a kai ell 2 2 a el e io O 3 n cc a H e 3 bl B e EH z9 O O B a Ze 2 S Ei wW D GEE System Monitor Installed status Base TEE Base Module MasterPLC gt Main base n Powe Q25PRH 0371 QJ61 Unmo ox Pl einen aaa oe 2 GX Developer PY Backup mode 325 32 z 2 86 Be Llu W az TEs Standby system Parameter status Mode 1 0 Address 0o 2 40 60 System monitor 1 2 3 4 C Online module change In
7. 6 2 Redundant System Network Overview A redundant system can be applied to the following five networks Network modules must be mounted on the main base units z e MELSECNET H PLC to PLC Network e MELSECNET H Remote I O Network e Ethernet e CC Link 6 PROFIBUS DP i A 20 The above networks can continue the data link and communication with external devices Ei Q even when an error occurs in the control system Do 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 the corresponding network manual for details of the network used M a lt The network modules for networks other than the abovementioned and serial 9 communication modules etc cannot be mounted on a main base unit for redundant 5 x system Mount them to the remote I O station or extension base unit in the MELSECNET H Remote I O network i fa Personal 2 lt 6 Lu computer AnACPU AnUCPU AnNCPU 5 22 Normal Normal Normal ae 5 Ethernet station station station 3 T rea Tl ane C MELSECNET H MELSECNET 10 Mode PLC to PLC nemor Multiplexed Remote Master Station Multiplexed Remot
8. b System switching requested by the network module e When the control system MELSECNET H network module or the Ethernet a interface module detects a communication error or wire break the module 2 oc requests system switching to the CPU module The standby system z MELSECNET H network module or the Ethernet interface module does not request system switching even if the module detects a communication error or wire break e When the PROFIBUS DP master module detects a module fault or a n E communication failure with DP Slaves the module requests system switching to the CPU module The standby system PROFIBUS DP master module Eg does not request system switching even if the module detects a module fault cas 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 y a Diagram 5 24 shows the processes that take place when the system switching S request is received from the network module g Q x Ethernet Communication System A disconnection System B a Control System Standby System System A System as a o 7 wae System switching request E z Z a a BLE a arse l Ee z SES
9. 2 Redundant System Operation at System Switching due to Control System Error 2 When system switching occurs due to a control system error the data link is amp gt continued by the network module mounted on the new control system 2 Example Diagram 6 8 shows the redundant system operation when a stop error occurs in the control system CPU module on the assumption that the control system network 6 module is the control station of station No 1 and the standby system network module E is the normal station of station No 2 Eg O no Normal station Normal station Station No 3 Station No i air a E def uy le z Oo z xe Q L MELSECNET H PLC to PLC network D gt z Control Control station Standby Normal station system Station No 1 system Station No 2 z S n ama 1 f lt e E f H f KI E ros o p M a z 5 a OFS 7 Peg Tracking cable J Stop error occurs in the control system CPU module fi n a a Normal station Normal station z2 Station No 3 Station No 4 a2 E a 2 a wW D fe m F el E 6 z A lt MELSECNET H PLC to PLC network gt Zo o Control station Normal station Station No 2 z g Station No 1 Sub control station in Standby system Control system TZ g a g The new control s
10. System B System A a m m a St 3 ZO z 22 Tracking cable T2 System A connecter 0 Z o 6 22 O Diagram 5 3 System A and System B when System A Connector Is Connected to Right System Refer to Chapter 3 for tracking cable specifications and connection Z E O fe ae i W a oc E 5 1 Basic Concept of Redundant System 5 3 5 1 1 Determination of System A System B D REDUNDANT SYSTEM FUNCTIONS MELSEC TA ories 2 Confirming system A System B Identify system A and system B by checking the SYSTEM A and SYSTEM B LEDs of CPU modules Table5 1 Identify system A and system B by checking the SYSTEM A and SYSTEM B LEDs CPU Module LED LED Statuses Q12PRHCPU MODE BACKUP LED Name System A System B RUN CONTROL mE geen SYSTEMA ON oF __ USER SYSTEM B E SYSTEMB Refer to the following manual for details on the CPU module LED L QCPU User s Manual Hardware Design Maintenance and Inspection 3 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 mod
11. Tracking cable Fi Power ON OFF Power ON OFF Diagram App 16 The system when power supplies of both systems are temporarily OFF APPENDICES 3 System A starts as the control system when both systems are simultaneously powered ON The SM1519 is ON for one scan after the system A CPU module has run SP CONTSW K1 MO T SP CONTSW K1 MO GOEND GOEND Control system Standby system INDEX System A System B ooo000 ooo ooo000 nooo a of amma fo ia Tracking cable L Power OFF ON Power OFF gt ON Diagram App 17 The system when both systems are simultaneously powered ON After turning on one of the power supply modules turn the other one on within 3 seconds 4 Switching System B to the control system through a system switching instruction Standby system Control system System A a T System B a System switching o Tracking cable Diagram App 18 The system when System B is switched to the
12. a This chapter provides troubleshooting methods of redundant system a gt 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 O C7 QCPU User s Manual Hardware Design Maintenance and Inspection 7 The CPU module status can be confirmed by the LEDs which are situated on the front Zo face of the CPU module The CPU module LEDs necessary for troubleshooting of 26 redundant system are explained here lt Q12PRHCPU 6 1 one sacku O lt _ _ 7 eee eed ee SYSTEMA z 2 sete 8 E BAT 3 O pA ie 9 a 10 ci cn Oa 6 ae cr Zz 204 Diagram 8 1 CPU Module LEDs ag 5 ER ange Table8 1 LED Names and Explanations z W No Name Explanation wn Indicates the CPU module mode be lt 1 MODE LED On Green Q Mode a Flashing Green External I O Forced ON OFF has been registered g5 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 a The standby system CPU module in backup mode A The RUN STOP switch RUN position 22 2 RUNLED 86 An error that stops operation has been detected a Flashing
13. l m 2 Perform PLC write to i Tracking cable D standby CPU module I ee Soe l 56 1 Perform PLC write to control CPU module 2 8 TE GX Developer Program memory Program memory Perform PLC write _ for program B Before writing After writing Before writing After writing E Program A Program A Program A Program A gt _ Eo gx e m 25 Program B Program B Ae TZ Diagram 5 58 Procedure for Writing to the Control System and Standby System When CPU Module Writes Gi Program during STOP p 22 O E O g zZ E Q fe ae i 5 a oc H 5 6 Writing To The Both Systems Using GX Developer 5 99 5 6 1 Writing to the CPU Module in STOP Status D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 3 Precautions a When Write to the Other System CPU module is Disabled In the following cases the data will be written into only the CPU module to which GX Developer is connected e Either system power is OFF e Either system is resetting e Hardware failure on either system e Watchdog timer error error code 5000 or 5001 occurs on either system CPU module e Tracking cable disconnection or malfunction In these cases the error dialog box in Diagram 5 59 will appear on GX Developer E MELSOFT application i Connected system has a communication problem Please execute it again after c
14. Multiplexed Remote Master Station Multiplexed Remote Sub master Station Control system y Standby system y H B B E a E O O ae 1 a H a kd T 36 paH l D o E a oO re Tracking cable OZ O no MELSECNET H Remote I O network Remote 1 0 Remote Remote 1 0 station station station i 5 o i o a o Ea e f e sf a B E l l 6 4 Ble s E S lt fue E T 2 Multiplexed Remote Sub master Station Master Station operation ps L lt ep Control system WSs Dox ia al g meas dons Al Bl Sra Error fault p a o e Tor z JEg Tracking cable ja 2 MELSECNET H Remote I O network on Z qZz Remote I O Remote I O Remote I O a2 station station station 56 A o z o 2 wW D T ee j 3 a a a a J 2 Ea z a Ee a Diagram 1 5 System Configuration for MELSECNET H Remote I O Network a 2 Ax ZO ae lu W Pe ms 0 Z o 6 22 xO G ms Q fe ae N W a oc E 1 2 Features 1 15 1 OVERVIEW MELSEC Aeres c PROFIBUS DP When the PROFIBUS DP master module detects a fault or communication failure with slave stations the both systems are switched so that the communications can be continued Control system Standby system Tracking cable Bus ter
15. Memory Card Type system SRAM card Flash card ATA card are the same 1 An error occurs because 2 An error occurs because the the memory card setting memory card type is SRAM 1Mbyte status is inconsistent different SRAM 1Mbyte ATA Card Flash Card MITSUBISHI Notmstalisd msuesi wrsuaisii VELSEG MELSES MELSES 1M Control Standby system system jz T g fz E N 2 a amp j a T mE jeje TTT CoOU 0Cos f Col T6Cole TARLA ICAIKICAINE 5 Tracking cable Diagram 5 15 Memory Card Setting Status Consistency Check b Inconsistency Errors Table5 17 shows the inconsistency errors that occur when the card setting statuses are inconsistent Table5 17 Memory Card Setting status Inconsistency Errors Execution Conditions Error Description e When both systems are powered ON The following stop error occurs in the control simultaneously system and standby system CPU modules CARD TYPE DIFF error code 6040 or 6041 e When both system CPU modules are unreset RESET L CLR switch is set to the neutral position simultaneously If the CARD TYPE DIFF error occurs in the
16. CAINILGAIA I Ue Coz ot Tracking cable GX Developer Diagram 5 102 Remote Reset Operation When Control System CPU Module Is in STOP Status and Standby System CPU Module Is in RUN Status 5 138 5 10 Redundant CPU Functions Restricted in Redundant System 5 10 2 Remote Operation for Redundant System D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 2 When watchdog timer error has occurred in the standby system CPU module When a watchdog timer error has occurred in the standby system CPU x gt module only the control system CPU module is reset and the standby system w 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 Z E
17. 5 1 1 Determination of System A System B In a redundant system one of the systems connected with a tracking cable is referred to a as System A and the other System B w System A and System B are determined by the direction of the tracking cable i e 2 connectors 1 Determination of System A System B 5 The system that includes the CPU module connected with the tracking cable system Z A connector will be System A and the other one with the system B connector will be ae System B 28 a 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 l lt System A System B 9 7 H E BEPPE Bl el Gl pl O 8 el e g lel i lel A 30 a SIE aA a BIAS Cl es al BIG Tracking cable e 2 lt woe System A connecter System B connecter az Ici Ir St a A B Tor Diagram 5 2 System A and System B when System A Connector Is Connected to Left System 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 Lu 12 gt no E Zz lt x a Zz Q W a 7 2 O QO 2 u
18. colled ICON TC Ola Leol leal Tracking cable GX Developer Diagram 5 99 Remote Reset Operation 5 136 5 10 Redundant CPU Functions Restricted in Redundant System 5 10 2 Remote Operation for Redundant System D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series Remote reset operation cannot be performed for the standby system If remote reset operation is performed for the standby system by GX Developer the error dialog box in Diagram 5 100 will appear p gt 4 Cowok manuke tho uneti vdi thre PLE pet coraed beye Diagram 5 100 Error Dialog Box Displayed on GX Developer b In the separate mode or debug mode Z In the separate mode or debug mode remote reset can be executed for only the lt se 5 k system specified in the Connection setup of GX Developer The operation status ae og Zz of the unspecified system does not change Ael Control Standby wW E i z z K xe S Tracking cable a ci GX Dev
19. Control system CPU module Standby system CPU module ON green Q12PRHCPU Q12PRHCPU MODE BACKUP MODE BACKUP RUN CONTROL RUN CONTROL ERR E SYSTEMA O ERR SYSTEMA USER SYSTEMB ON green USER SYSTEMB BAT BAT BOOT BOOT ON red OFF Diagram 5 82 LED Indications during Standby System CPU Module Operation 5 7 Memory Copy From Control System To Standby System D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series b Operations when executing Memory Copy The operation at memory copy execution is shown in Diagram 5 83 Specify memory copy Perform memory copy Control system Standby system Control system Standby system ICAIDIGANA eol Neola Sol leoT as Tracking cable Tracking cable 1 Memory copy from GX Developer 2 Begin copying to the standby sytem CPU Q GX Developer GX Developer Memory copy completed Control system Standby system ol aHa i 8 ELE a a E O l S e AE B Tracking cable 3 Copying to the standby sytem C
20. When accessing to a redundant system the host OPS can automatically identify and z directly access to the control system if it has been specified as destination in ce a advance 3 ra fe T Ethernet e BE Control system Standby system 58 A a E l z Tracking cable Z xe Q x fue E Control and network m automatic system switching 5 ag w amp Ethernet oe AZA OES Standby system Control system eda El o ange a ae a By E a E 4 3 ai g H gt Tracking cable 2 Zo a Diagram 1 9 System Configuration for Ethernet 36 ag TR 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 a n Some models are irrelevant Section 2 3 A Therefore equipments within factories can be utilized maintenance costs can be Z reduced and the system can be expanded 5s re 0 Z 2 no 22 eC oO zZ E Q ae N 5 a O oc E 1 2 Features 1 19 1 320 OVERVIEW MELSEC TA eerie 9 Online module change hot swapping The I O module mounted on a main base unit with a redundant CPU module and the module mounted on a remote I O station can be replaced online hot swapping using GX Developer gt Section 2 4 Note that a module mounted to the main base unit cannot be replaced online when the ext
21. Function Connection destination specification system system specification Batch read O O O O Batch write O O O O O Random read O O O O O Device memory Test Random write O O O O O is Monitor data registration x x x O O z Monitor x x x O O Multiple block batch read O O O O O Multiple block batch write O G O O O Intelligent function module Pa Bia O O O O O Batch write O O O O O Remote RUN O O O O O Remote STOP O O O O PLE CPU Remote PAUSE O O O O Remote latch clear O O O O O Remote RESET O O O O O CPU model name read O O O O Directory file information read x x x O O Directory file information search a x x O O New file creation x x x O O File deletion x x x O O File copy x x x O O File File attribute change x x x O O File creation data change x x x O O File open x x x O O File read x x x O O File write x x x O O File close x x x O O 1 When system switching occurs during MC protocol communication via a module mounted to the extension base unit communication timeout may occur if both the old and new systems cannot respond Remark EEEE EFEEEFEEESEEEFEFEFFEFSEFEEEEEEEEEESESEEEE EE For details of each command refer to the following manual lt gt Corresponding MELSEC Communication Protocol Reference Manual eeeeseeceeoevoeeseeeoeaoeeeoceceaoeeeseeeeeeeeeoe eee eoeeeeeeeeeeeeaoe eee ee Appendix 7 Restrictions on Communication via Module Mounted to Extension Base Uni
22. 4 5 D100 D101 a o Tracking cable Diagram 5 18 Initial Start Mode Operation 5 28 5 1 Basic Concept of Redundant System 5 1 6 Start Mode System B Power the system off and back on g oo0000 Standby System Co lCo H eST 0eolsr el g kl 5 REDUNDANT SYSTEM FUNCTIONS MELSEC Eseries POINT After system switching the new control system will start up in the Hot start mode regardless of the start mode settings OVERVIEW 2 Hot start mode This mode is for performing 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 CONFIGURATION SYSTEM Control using Hot start mode TRACKING CABLE Tracking cable Power the
23. BACKUP ON green Standby system GX Developer Tracking cable separate mode change operation Change to separate mode Run in separate mode BACKUP lt ON amber Control system BAckKUPEI ON amber lt flashing oll lColz EJ HE ot GX Developer Tracking cable Diagram 5 33 Operation when Changing from Backup Mode to Separate Mode 1 When changing from the backup mode to the separate mode the RUN LED of the standby system CPU module will flash and will be in a stop status 5 4 Operation Mode Change Function D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series
24. When specifying System A using MC System switching activated protocol Multiplexed Remote Sub master Station Multiplexed Remote Master Station System A System B Control System Standby System om o g g jam a i i i ty I i 1 Tracking cable ee hee a a a a a a a a a a er ae I I Remote I O module gt MELSECNET H Remote I O network i 7 Serial communication I module Rema VO ston ona VO ston I When specifying System A using MC protocol Diagram 6 32 ommunication with System A CPU Module by MC Protocol 6 38 6 2 Redundant System Network Overview 6 2 5 Serial Communication Modules 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series
25. Standby system Control system E Coll 16S ColU U6olh COU TCOLsE Tracking cable Diagram 5 14 Basic system Configuration Consistency Check A consistency check is not executed for the followings e Model of battery set in the CPU module e Main base unit model and number of available slots e Serial Nos of modules mounted in the main base unit e Number of power supply modules mounted in the main base unit e Model of power supply modules mounted in the main base unit e Slots set to Open in the PLC parameter I O assignment e Modules being replaced online e Modules mounted on slots after the number of those in the PLC parameter I O assignment 5 20 5 1 Basic Concept of Redundant System 5 1 4 System Consistency Check 5 REDUNDANT SYSTEM FUNCTIONS Mi aL 3G Kel ceries b Inconsistency Errors Table5 14 shows inconsistency errors that occur when the basic system configurations are inconsistent OVERVIEW Table5 14 Basic System Configuration Inconsistency Errors Execution Conditions Error Description e When both systems are powered ON simultaneously The following stop error will occur in the control e When both system CPU modules are unreset system and standby system CPU modules RESET L CLR switch is set
26. Operation i As the target CPU module of remote RUN remote STOP remote PAUSE or remote 2 N latch clear select the CPU module of either system or the CPU modules of both zx 2O systems in the Connection Setup of GX Developer 25 re Remote operation Connection target information Connection interface COM1 lt gt PLC module Target PLC J Station no Host PLC type Q25PRH PLC status Rmn o Select when performing G GEZ mrga eemi Ens remote operation for the 5 CPU module of the SQ peration Specify execution destination Ge 5 az pic STOP Currently specified station system specified in Fe ie All stations Connection Setup 92 C Specific group 7 2 6 BoihysiemsiAtB lt q Select when performing remote operation for the control system and standby system CPU g modules 5 Diagram 5 96 Remote Operation Screen z a 2 5 10 Redundant CPU Functions Restricted in Redundant System 5 133 a 5 10 2 Remote Operation for Redundant System D REDUNDANT SYSTEM FUNCTIONS MELSEC TA eries a Remote operation for the system specified in the Connection Setup of GX Developer When Currently specified station is selected at the execution 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
27. When specifying control system using MC protocol Diagram 6 30 Operation for Communication with Control System CPU Module by MC Protocol b Communication by Nonprocedural Protocol Bidirectional Protocol For nonprocedural protocol bidirectional protocol communication with external devices can be performed using the control system CPU module s programs 6 2 Redundant System Network Overview 6 2 5 Serial Communication Modules 6 36 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series 2 Communication between External Devices and the Standby System CPU Module a gt oc a Communication by MC Protocol z Specify the standby system by MC protocol on each external device and perform the communication with the control system CPU module If the standby system is specified by MC protocol communication with the new standby system CPU module can be performed even when system switching occurs 6 Communication can be performed by MC protocol only E oO 2 i Multiplexed Remote Master Station Multiplexed Remote Sub master Station no Control system Standby system hy B g foal
28. Personal computer Ethernet communication with upper layer AnACPU AnUCPU AnNCPU m Normal station Normal station Normal station z O g MELSECNET H MELSECNET 10 Mode PLC to PLC network communication with other stations lt E QCPU QnACPU Q4ARCPU Normal station Normal station Normal station 2 Control station c 5 Oas LIN e55 B amp R ce Be DP Slave DP Slave E PROFIBUS DP I O control E n l D CC Link zo I O control communication with 9 external systems a2 TE Remote 1 0 station Remote device Intelligent device lt A of station station s a lt lt i pi h NN i a 5 al MELSECNET H Remote I O network Eo I O control communication with external systems lt lt 2O Bmp i lu W az oma VO saton Remote I O sanon frenos VO saon Diagram 2 1 Example of Redundant System Configuration g T 1 In a coaxial bus system use double shielded coaxial cables Se Refer to the following manual for the double shielded coaxial cables ga lt 3 Q Corresponding MELSECNET H Network System Reference Manual Remote I O Network 2 When connecting the extension base unit use the Redundant CPU whose first 5 digits of serial a No is 09012 or later in both systems Z j ae N 5 a oc 2 1 System Configuration 2 2 SYSTEM CONFIGURATION E POINT
29. Q62P CPU module Q62P CPU module W x D 2a l KERR I ERR 593 n ERR A 100V 200VAC ol JAE rar O4 FG FG Sar AC i O47 LG LG cfu PR lO 7 INPUT INPUT ao T O AC100 AC100 to 200V to 200V Redundant type extension base unit a Q65WRB gt la64RP Q64RP I O module o ako Extension cable a 55 A wW D a m Ol 4 U U 2 ERR a 7 ERR i C Olt FG Ol FG INPUT e T INPUT P ER proT actioo P actoo A eine le eal to 200V to 200V Grounding 2 100V 200VAC 29 4 BG AC all Peccooccce cZ 100V 200VAC 0 zZ Diagram 4 3 Example of Wiring to a Power Supply Module o TO 1 Operation of an ERR terminal is as follows aS r 5 r act lt When mounting power supply module to main base unit gt 20 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 F lt When mounting redundant power supply module to redundant type extension base unit gt Z The ERR terminal is OFF open when AC power is not turned ON when fuse of the redundant 3 power supply module is blown or when the redundant power supply module breaks down Fe z oc E 4 2 Wiring 4 5 4 6 PROCEDURE FOR STARTING UP A REDUNDANT SELL M BLS AG FY caries POINT 1 Use the thickest possible max 2 mm 14 AWG wires for the 100 200VAC and 24VDC power cables Be sure to twist these wir
30. EAIRICANA Colo l COU TCOU ICOIDICOIKA Tracking cable Replace after turning OFF the standby system power GX Developer Diagram 8 26 System where Standby System Network Module Is Replaced 2 Replacement Procedure The replacement procedure for network modules is indicated in Diagram 8 27 l 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 standby system using GX Developer s system switching Refer to Section 5 2 for system switching using GX Developer Turn the Standby System s Power Supply OFF 8 38 8 3 Replacing Module in Redundant System 8 3 5 Network Module Replacement Procedure 8 TROUBLESHOOTING M al ECLA series Disconnecting the Cable Disconnect the network cable from the target network module m Refer to the manual of the network module for disconnecting the network cable ma W 3 Replacing the Standby System s Network Module 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
31. olm 1 Stop Error has occured 2 Perform system switching s Eom GAIMANA ieaie Tracking cable MELSECNET H Remote I O network i Output is preserved during system switching Remote O station station No 3 Remote I O station station No 2 Output is preserved during system switching Diagram 6 14 Redundant System Operation at System Switching 6 16 6 2 Redundant System Network Overview 6 2 2 MELSECNET H Remote I O network 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series 3 Redundant System Operation when a Communication Error Occurs in the MELSECNET H Remote I O Network z gt jam a System Switching Procedure z When a communication error occurs in the MELSECNET H remote I O network system switching is performed according to the following procedure so that the data link will be continued Zz 1 When a communication error occurs in the MELSECNET H remote I O E network the control system network module issues a system switching se 20 request to the control system CPU module GZ no 2 When receiving the system switching request f
32. r QCPU Q mode QCPU Qmode QnPHCPU QnACPU QnACPU QnPRHCPU QCPU Q mode QCPU Q mode QCPU Q mode a Pursose Programming Programming Programming QnACPU Programming Programming E p Manual Manual PID Manual Process Programming LEUEN Manual 5 Common Control Control LEUEI EI sf 09 MELSAP L Structured Text m 9 Instruction Instruction Instruction A 6 Confirmation of usage of a sequence instructions basic instructions application Details instructions etc z a q Confirmation of dedicated S instructions for PID control 3 Confirmation of MELSAP3 s system configuration performance specifications Details ci functions programming 52 rao debugging and error codes d 35 Confirmation of the RZA programming method 8 z a specifications functions etc Details ESAS required for SFC programming of the MELSAP L type W Confirmation of the p 4 N programming method of the Details Eo structured text language 5 6 55 A wW D GEE W E n gt N E 22 Ax ZO Be lu W Pe ms Oo Z o 6 95 act eC zZ E Q fe ae N 5 a re OVERVIEW SCTE cries b High Performance Model QCPU Table1 3 List of user s manuals of high performance model QCPU Purpose Confirmation of part names and specifications of the CPU module _ _ _ O M
33. 1 Tracking 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 the asynchronous tracking mode lt _ Section 5 6 2 5 5 Tracking Function 5 93 5 5 7 Tracking Mode OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol wW 12 gt no E zZ lt z Q W a 7 2 O O Z 5 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS MELSEC TA eries 2 Synchronized Tracking Mode This method performs tracking to the standby system for each scan while the control system CPU module is executing the END processings If the previous tracking is not complete during END processing the system will wait and perform the next tracking after it has been completed 2 types of synchronized tracking modes are available synchronized tracking mode and program priority mode The default tracking mode is synchronized tracking mode Change the tracking mode settings at the tracking settings in the redundant parameter settings a Contro
34. 2 Redundant system Operation at the time of System Switching a When System Switching Occurs due to Control System Error When an error occurs in the control system and system switching occurs the new z 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 6 lt x jag Master Station Standby Station a f Station No 0 Station No 1 A as System A Control System System B Standby System eee fl Le i 40 EIE a il I g E 7 S 8 S Tracking cable A 2 i Q g CC Link go z Remote I O station station No 2 a woe 204 Standby Master Master Station T Z 5 Station Operation Operation 8 5 2 Station No 1 Station No 0 A a System A Control Syst m VY System B Standby System Stop Error al e g E Tracking cable ZE g CC Link a5 Remote I O station station No 2 ez Diagram 6 26 Operation at System Switching due to Control System Error Lu 2 gt 2 Zz lt q Q Zz Q W a n 4 iva O z 2 W Zz PROGRAMMING CAUTIONS TROUBLESHOOTING 6 2 Redundant System Network Overview 6 29 6 2 4 CC Link 6 REDUNDANT SYSTEM NETWORKS 6 30 MELSEC TA eries b When System Switching Occurs due to Communication Error in Network other than CC Link When a com
35. Col 1Coa S y eo e Sam l o 2 sia Tracking cable ee ti 2 N 5a RUN STOP Status RUN STOP Status S Z 2 Check operating status Be 5 Check the parameter usable drive ne Diagram 5 11 Consistency Check Points Between Systems A and B Table5 9 Consistency Check Points Between Systems A and B Check Points Description Z 9 Checks parameters programs and initial device values 22 1 File Contents Se Checks the memory capacity of the area for online change of multiple blocks 92 2 Operating Status Checks the CPU module operation status RUN STOP PAUSE Ss j f Checks the CPU modules I O modules and network modules mounted on the 3 Basic System Configuration f main base units w k Checks the set memory card setting and the type i e SRAM Flash and ATA 4 Memory Card Setting Yp 8 card 3 5 Parameter Valid Drive Settings Checks the parameter valid drive settings dip switch SW2 SW3 O ve H 5 1 Basic Concept of Redundant System 5 15 5 1 4 System Consistency Check D REDUNDANT SYSTEM FUNCTIONS AG Q series Table5 10 Consistency Check Execution Conditions between System A and System B Conditions 1 Description i l Standby System Contro System P Operating Basic System Memory Card Parameter Valid Execution Timing Operation Mode Operating Operating File k
36. Unit bps Unit bps 50 OFy 14400 064 300 004 19200 074 600 Olh 28800 08H 1200 024 38400 09H 2400 034 57600 OAy 4800 044 115200 OBy 9600 05H 230400 0Cy 230400bps is applicable for the CH1 side of the QU71C24N R2 R4 only e When connecting external devices to two interfaces CH1 and CH2 the total of communication speed of two interfaces should be within 115200bps 230400bps for the QU71C24N R2 R4 When 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 004 to the interface side where GX Developer connection is set in the communication protocol setting The serial communication module can operate at speed set for GX Developer side Appendix 6 Precautions for Using Serial Communication Module App 35 APPENDICES MELSE TA eries The program example for mode switching is shown in Diagram App 25 For the I O signal is X Y80 to X Y9F x60 M11 M12 X83 X84 M50 aa oe a MOV Ki DO Mov H85B0 D1 TO H8 H90 DO K2 SET Y82 X86 7 RST 82 FROM H8 H203 D2 K1 f D2 Ko SET M50 M50 shee SENS SSS SES ese eein eee M ee Rees cme senias 29 Setting value change of buffer memory specific use area
37. O Zz Q O T o wW m O iva E 8 3 Replacing Module in Redundant System 8 37 8 3 4 I O Module Replacement Procedure 8 TROUBLESHOOTING MELSEC TE ories 8 3 5 Network Module Replacement Procedure 1 Network Module Replacement The control system network module cannot be replaced while the redundant system is running In this case switch its system to the standby system then start the replacement operation network module Control system Standby system nooo ooo oooo00 nooo ojele iii Soleo Col eolz Cols leolzs ecole os o Tracking cable A Replace after using GX Developer to GX Developer switch over to the standby system Diagram 8 25 System where Control System Network Module Is Replaced Perform replacement of the standby system s network module after switching the standby system s power supply OFF The power supplies of standby systems can be turned OFF even when the redundant system is active network module y system Control system Standb e
38. RST Y10 After measures A er Y10 2 2 2 PLS Hl Delays SET Y10 by one scan from PLS M1 Delays RST Y10 by one PLS Mti scan from PLS M11 Diagram 7 17 Program Example when there is Response Input to Output 7 18 7 4 Precautions at System Switching Occurrence PROGRAMMING CAUTIONS MELSEG TA series b Output is returned corresponding to external input m id Response input X10 X z ro I Output Y10 i gt zZ fe Program example z0 A ble no Before measures HO X10 Y10 oH SET Y10 M10 X10 Y10 il lH mp P_ rs Y10 z O Oo zZ xe Q After measures E M of SET Y10 Ho x10 Y10 m 2 1 HF PLs M Delays SET Y10 by one g o scan from PLS M1 TIo M11 coe Ey Y10 293 OES H10 X10 Y10 ofa 9 t F _ TSTS his W11 Delays RST Y10 by one E be ae scan from PLS M11 Diagram 7 18 Program Example when there is Response Output to External Input fi 2 bo 56 Ze S A TE POINT Set Do tracking of Signal flow memory tracking setting at Tracking settings of Redundant parameter 2 z 2 a 2 Precautions regarding timer 5s Pay attention to the following points regarding timer at the time of system switching T2 occurrence 1 The present value of timer at the first scan of the new control system CPU module at the time of system switching occurrence 2 Depending on timing of system switching occurrence such as turning
39. System A and Siciom B car be identi vy chockes whei Ne mucal splays Eystan A GacreTinoting Rag AMINT anc Eyrie Y Osoron fag 5415127 are ON te OPF Takes 2 Contirming SMI51T seed SMYHTT to leet Syston A and System amp Sans OW OFF Sen oer ON 57 Basic Goncaya of Rauca Syston l 51 7 Determination of Sysiom Ayatom 8 Section title The section of the open page is shown at a glance DSE C pana A 17 A 18 In addition this manual provides the following explanations ES POINT Explains the matters to be especially noted the functions and others related to the description on that page Provides the reference destination related to the description on that page and the convenient information eeeeeseeeseeveeeeeeneeeseeeeeeseeeeeeeeeeeseeeeeeseeeeeee eee 8 GENERIC TERMS AND ABBREVIATIONS Unless otherwise specified this manual uses the following generic terms and abbreviations to explain the Redundant CPU Generic Term Abbreviation Description Basic model QCPU Generic term for QOOJCPU QOOCPU and Q01CPU modules High Performance model QCPU Generic term for Q02CPU QO2HCPU QO6HCPU Q12HCPU and Q25HCPU modules Process CPU Generic term for Q12PHCPU and Q25PHCPU Redundant CPU Generic term for Q12PRHCPU and Q25PRHCPU QCPU Generic term for QNCPU QnHCPU QnPHCPU and QnPRHCPU QnCPU Generic term for Q02HCPU QnHCPU Generic
40. Zz lt q Q Zz Q W a n 4 iva O z 2 W Zz PROGRAMMING CAUTIONS TROUBLESHOOTING 6 3 Communication between the Both Systems CPU Module and GOTs 6 47 6 3 4 When Connecting GOTs to a Ethernet 6 REDUNDANT SYSTEM NETWORKS 6 48 MELSEC TA cries 2 Communication method a GOT1000 series The GOT can monitor the control system of the redundant system by setting the Q redundant setting The monitoring target can be changed automatically even when system switching occurs When connecting via the extension base unit the control system is always monitored For the function to enable this automatic changing of the monitoring target at the GOT refer to the following manual lt gt GT Designer2 Version2 Screen Design Manual 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 necessary to create a screen to switch station No of systems A and B to monitor when system switching occurs in the redundant system For details refer to the following manual lt GOT A900 Series User s Manual GT Works2 Version2 GT Designer2 Version2 compatible Connection System Manual 6 3 Communication between the Both Systems CPU Module and GOTs 6 3 4 When Connecting GOTs to a Ethernet 6 REDUN
41. paren O Number 00H to 1FH 20H to 3FH 40H to 5FH 60H to 7FH KOON EGON aE Je ol UC ol t Tracking cable Module installation range Module installation range Diagram 2 12 Number of Slots Occupied by Redundant CPU and I O Numbers of Main Base Units 2 4 System Configuration Cautions 2 SYSTEM CONFIGURATION Mi aL E0 Q series 7 Restrictions on online module change Hot Swapping The online module change hot swapping using GX Developer can be performed to the main base unit extension base unit and MELSECNET H remote O station where the Redundant CPU is mounted The target modules of online module change are shown in Table2 5 N OVERVIEW Table2 5 Target Modules of Online Module Change Hot Swapping 6 lt x Mounting position 3 Main base unit Eg Module Function version Extension base MELSECNET H 25 where Redundant gt i unit Remote I O station CPU is mounted Input module 7 eu O O Output module oe O O lt I O combined module ou O O 9 Analog input module C or later x O O 5 Analog output module C or later x O O E Temperature input module C or later x O O Temperature adjustment module C or later x O O z Pulse input module C or later x O O Oe o n a 1 When the extension base unit
42. Co Co zm CONC oL e a e col Coles Tracking cable T Replace after using GX Developer to switch over to the standby system GX Developer Diagram 8 23 I O Module Replacement System during Power ON 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 above cases refer to the following manual lt gt QCPU User s Manual Hardware Design Maintenance and Inspection 8 36 8 3 Replacing Module in Redundant System 8 3 4 I O Module Replacement Procedure 8 TROUBLESHOOTING MELSEC A series 3 Replacement Procedure during Power OFF The I O module replacement procedure is shown in Diagram 8 24 z W 3 Confirm the I O Unit Targeted for Replacement Confirm that the I O unit to be replaced is the standby system CONTROL LED is off When Ee replacing the I O unit for the control system use GX Developer to switch it to the standby system 2 x Refer to Section 5 2 for system switching using GX Developer se i be O Turn the Standby System s Power Supply OFF Be l Removing the Terminal Block Connector from the I O module Remove the termi
43. Program example Before measures 7 TO R z0 ot H SET Y10 pZ T10 i ae 4 4 RST Y10 After measures z O Oo 0 i set vio J TO E a4 PLS H Delays SET Y10 by one scan from PLS M1 M11 5 RST Y10 J T10 amp Del RST Y10 b a E e Ezo cr Zz 204 aqaz2a OFS Diagram 7 20 Program Example when Outputting by timer contact RE g n POINT 2 nO Set Do tracking of Signal flow memory tracking setting at Tracking settings of 56 Redundant parameter az cw 3 Precautions regarding writing data from the GOT and external device i etc s Pay attention to the following points regarding writing data from the GOT and external zg device etc 5S mm 1 The tracking data may not be reflected to the new control system CPU module ais depending on the timing of the system switching occurrence such as turning power supply OFF In this case data written immediately before switching systems by the GOT or external device may disappear Rewrite data after switching systems Z o eo g Da ET ao TROUBLESHOOTING 7 4 Precautions at System Switching Occurrence 7 21 PROGRAMMING CAUTIONS MELSEC TE ories 7 5 Precautions of Programming when Connecting Extension Base 7 22 Unit This section describes the precautions of programming when connecting the extension base unit 1 2 3 4 Precautions for using PX Developer As for the following functions use
44. 3 Execution of Write to PLC Click the Execute button As the following confirmation dialog box appeas click Yes MELSOFT series GX Developer d Execute e Diagram 4 11 Execution of Write to PLC Confirmation Window 4 7 Writing Parameters and Programs to CPU 4 11 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE A W n gt n f Zz lt x 5 z a W oc S r lt we Of TE an REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING PROCEDURE FOR STARTING UP A REDUNDANT SELL Mi aL 26 FY conics 4 8 Restarting System A and System B Power on system A and system B again or set the reset switches of system A system B CPU modules to neutral position in order to restart the redundant system 1 Powering supply ON again Power off system A and system B and then simultaneously power on the both systems 2 Setting the Reset Switches of CPU modules to Neutral Position Set the RESET L CLR switches of system A and system B CPU modules to the RESET position and then simultaneously set the switches to neutral position ae CPU module RESET L CLR Switch RESET _L CLR Resetting 4 RESET L CLR Unreset Diagram 4 12 Setting the CPU Module RESET Switch to Neutral Position 1 Power on one system within three seconds after powering on the other system 2 Set the reset switch of one C
45. 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 lt _ gt Section 5 1 4 TRACKING CABLE A W n gt n 2 A lt a Zz a W oc aj X lt aS oi ze aw REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 4 3 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM MELSEC TA cries 4 1 Mounting Modules 1 Procedure for Mounting Modules Mount a module to the main base unit and the extension base unit in the following procedures a Insert the module fixing latch into the module fixing cutout firmly so that the module fixing latch may not come off the module fixing cutout b Using the module fixing hole as a support install the module onto the base unit by pushing it in the direction of arrow Base unit sales a latch module fixing projection Module installation lever Module Module fixing cutout Diagram 4 2 Procedure for Mounting Modules 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 in
46. D REDUNDANT SYSTEM FUNCTIONS Mi aL 20 fel ceries b Errors that allow selection of operation For the following errors the operation can be selected to continue or stop in the PLC parameter s PLC RAS settings In the parameter default settings all errors are set to stop 1 Operation error including SFC program 2 Extension instruciton error 3 Blown fuse 4 I O module verification error 5 Intelligent program execution error 6 Memory card access error 7 Memory card operation error 8 External power supply OFF As the I O module verification error is set to stop when an error occurs a stop error occurs in the control system and system switching occurs However as the new control system also detects the I O module verification error and stops operation the redundant system stops the control If the I O module verification error is set to continue even if an error occurs the system switching does not occur and the operation continues at the I O No prior to the error 5 26 5 1 Basic Concept of Redundant System 5 1 5 Self Diagnostics Function 5 REDUNDANT SYSTEM FUNCTIONS MELSEC fA series 4 Self Diagnostic at Startup of Redundant CPU The redundant CPU diagnoses the system based on the points described in Table5 19 z when the redundant system is powered
47. Then the PRG MEM CLEAR error code 6400 stop error will occur in the z standby system CPU module However if a stop error has occurred before memory copy the PRG MEM CLEAR is not detected z 2 Memory copy is stopped when any of the following operations is performed E during memory copy 23 At this time the memory contents of the standby system CPU module will be GZ illegal 2g Perform any of the following operations after confirming that memory copy is completed e Power off the control system or standby system g e Reset the control system or standby system CPU module 5 e 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 2 Tracking cable fault 5 Pag d How to confirm memory copy completion woe Completion of memory copy can be confirmed by the special relays and GX REZ Developer FER 1 Confirmation by special relays When memory copy is completed the special relay Memory copy to other system status flag SM1596 turns off and Memory copy to other system completion flag SM1597 turns on Check whether SM1516 and SM1597 are ON or OFF to confirm memory copy completion Also whether memory copy is normally completed or abnormally completed can be checked by the special register Memory copy completion status SD1596 e When memory copy is normally completed SD1596 0 e W
48. 100 H yioo H System A CPU module When M0 is set to ON Y100 is also set to ON Set Y100 external output to ON System B CPU module s Y100 external output will be set to off because Y100 is OFF Circuit is added to System A CPU module System B CPU module Control system C Standby system gt MO Abort tracking transfer due requested from within GX Developer peo MO o l Y100 tz o run write operation 4100 n Refresh to the network module MO Y100 4 Perform system switching due to a stop error in the control CPU module Control system Standby System Standby system Control System Refresh to the network module System B CPU module When M0 is set to ON in the System B CPU module Set Y100 external MO MO Y100 H Y100 gt C3 MO MO ee Y100 fi 1 i100 m mm H output to ON Refresh to the network module Y100 external output OFF ON OFF ON When a system switching occurs the output undergoes chattering Diagram 5 64 Operation When System Switching Occurs during Online Program Change 5 6 Writing To The Both Systems Using GX Developer 5 6 2 Program Change While CPU is Running 5 REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series b Wh
49. Does not execute input Does not execute output Does not execute Executes the function output it Executes the function Does not execute auto refresh Does not execute auto refresh 1 When a stop error occurs in both system CPU modules all output Y to the remote I O station is turned off Remote I O station output can be held when a stop error occurs in both system CPU modules Please refer to the following manuals for information on how to hold remote I O station output L gt Q Corresponding MELSECNET H Network System Reference Manual Remote I O network CC Link System Master Local Module User s Manual 2 Indicates refresh of SB Link special relay SW Link special register used for MELSECNET H PLC to PLC network MELSECNET H Remote I O network and CC Link 5 4 Operation Mode Change Function D REDUNDANT SYSTEM FUNCTIONS In Separate Mode Control System Standby System During Normal RUN and During Resume Error During Stop During Stop Enor Executes the program Does not execute the program During Normal RUN and During Resume Error j During Stop D uring Stop Ero Executes the program 3 Does not execute the program Reflects the operation result of Reflects the operation result of the control Polas the standby Holds system system ON OFF ON OFF Executes it Executes it Does not execute the check Does not exec
50. Does not execute refresh No change from before operation mode change If Separate Mode is changed to Backup Mode when the RUN Led is flashing the RUN LED will turn off D REDUNDANT SYSTEM FUNCTIONS From Separate Mode to Backup Mode EEE Control system Standby system Continues execution Stops Stops continues Stops continues Takes over the current setting Takes over the current setting Takes over the current setting Changes to the DI status interrupt disable Takes over the current setting Takes over the current setting Takes over the current setting Takes over the current setting Takes over the current setting Takes over the current setting Continues the instruction exe cution Continues the instruction execution Takes over the current setting Takes over the current setting Takes over the current setting Takes over the current setting Takes over the 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
51. MELSEC keres 3 Fixed scan execution type Program When system switching occurs the execution of fixed scan execution type programs is suspended until system switching is complete When system switching is complete the new control system CPU module starts counting the fixed scan interval time from 0 Therefore the fixed scan execution interval time is increased T q as shown in Diagram 7 8 The maximum value for the extension time is T q when qa q Control system N New standby system 2 System switching activated fixed cycle execution type Control system Program z z Scan execution type Nf 5 i y Program i New standby system Qa a a E E E L AD n Standby system Begin system switching P System Switching complete fixed cycle execution type A s 5 Program a SS jj New control system Sean execution type a gt 1 Program Extension of fixed cycle interval Standby system New control system gt a Fixed Cycle Interval T System switching time a Period between starting scan execution type program and system switching Diagram 7 8 Operations of Fixed Scan Execution Type Programs at System Switching 7 2 Cautions on Fixed scan Clocks Programs PROGRAMMING CAUTIONS MELSEC Aeres 4 Interrupt by the Internal Timer 128 to 131 When system switching occurs execution of interrupt is suspended until system z switching is complete a
52. QCPU Q mode QCPU Qmode QnPHCPU QnACPU QnACPU QnPRHCPU QCPU Q mode QCPU Q mode QCPU Q mode a Pursose Programming Programming Programming QnACPU Programming Programming E p Manual Manual PID Manual Process Programming LEUEN Manual 5 Common Control Control LEUEI EI sf 09 MELSAP L Structured Text m 9 Instruction Instruction Instruction A 6 Confirmation of usage of a sequence instructions basic instructions application Details instructions etc z a q Confirmation of dedicated S instructions for PID control 3 Confirmation of MELSAP3 s system configuration performance specifications Details ci functions programming 52 rao debugging and error codes d 35 Confirmation of the RZA programming method 8 z a specifications functions etc Details ESAS required for SFC programming of the MELSAP L type W Confirmation of the p 4 N programming method of the Details Eo structured text language 5 6 55 A wW D GEE W E n gt N E 22 Ax ZO Be lu W Pe ms Oo Z o 6 95 act eC zZ E Q fe ae N 5 a oc OVERVIEW c Process CPU Purpose Confirmation of part names and specifications of the CPU module MELSE TE ories Table1 5 List of user s manuals of process CPU Included in package QCPU Q mode CPU Module User s Manual Hardware Outline Mai 7 s aintenanc
53. Signal flow memory is tracking transferred 12 5ms When the extension base unit is not connected Signal flow memory is not tracking transferred 20 5ms Signal flow memory is tracking transferred 1 5ms System A System B l Control Standby Run program system system System switching Detect cause request of system E E switching System switching processing time 21ms System Execute Tracking transfer process Tre switching time T MELSECNET H CC Link PROFIBUS DP Tsw automatic refresh time Ta m y Standby system Control Run program system Diagram 9 1 System Switching Timing 1 The system switching processing time is shown for when signal flow memory is set to not track in the tracking settings of redundant system parameters 2 This is 0 ms when tracking processing is not complete 3 The maximum system switching time is shown 9 6 9 2 System Switching Time Q PROCESSING TIME FOR REDUNDANT SYSTEMS Mi aL 3G Kel ceries 1 Tracking Data Reflection Time Trc The reflection time for tracking data is calculated as shown below SE Z2 Ea oa Zz Ba wy Ww Om On co Oo 2 W 2 gt n Trc 1 Trci Trc2 Trc3 Trc4 ms Tracking data preparation time Tre Processing time for transfer data shown in 2 Trc1 to Trc4 o Table9 5 j a lt Table9 5 Processing Times of Tra1 to Tra4 Transfer Data Processing Time ms S
54. Standby System System A or System B is Specified When Control System Standby System System A or System B has been specified as the connection target using GX Developer or PX Developer monitoring tool switch the connection path and communication will continue with the specified system REDUNDANT SYSTEM FUNCTIONS ez wW 2 gt no z lt a z W a 9 X faa O z 2 W Zz PROGRAMMING CAUTIONS TROUBLESHOOTING 6 1 Communication with GX Developer and PX Developer 6 5 6 1 3 Cautions on Access from GX Developer and PX Developer 6 REDUNDANT SYSTEM NETWORKS 6 6 MELSEC TA eries Example If a line down occurs in system A during access when PX Developer monitoring tools is connected to that system and the connection target is specified as system A communication is continued with system A via system B j GX Developer 2 The line is down System A System B Control System Standby System Ethernet ooo ooo000 Colsm N ase System switching a tvs HETA C a When the line is down Tm ges Hil col leglm GAI E cD A
55. Tracking can be done in either backup mode or separate mode Control system Standby system a 16o Ls O CANGAA During END processing default set data is tracking forwarded Diagram 5 46 Data Transfer by Tracking Function 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 for tracking is changed data after the change will be tracked 3 Section 5 5 3 5 74 5 5 Tracking Function 5 5 1 Tracking Function Overview 5 REDUNDANT SYSTEM FUNCTIONS 2 3 MELSEC Eseries Tracking Data There are 2 types of tracking data tracking data based on the range set by the user and tracking data regardless of the settings i e automatic tracking data a Tracking Data Range Setting by User The tracking data range and tracking timing can be set by the user As the tracking data range has been set by default in the redundant CPU tracking will be executed even without the user making the tracking settings b Automatic Tracking Data The data will be automatically tracked regardless of the tracking settings The automatic tr
56. YES Does the number of Stages of extension base unit exceed specifications Change the number of stages of extension eter code 2010 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 compatible with extension base unit Hardware failure of the following modules is suspected eExtension base unit Extension cable Consult your local Mitsubishi representative explaining a detailed description of the problem 8 22 8 1 Troubleshooting Flow 8 1 10 When BASE LAY ERROR Occurs 8 TROUBLESHOOTING MELSE Eseries a z gt oc gt Is error code 2012 fe Is GOT connected to main YES Remove bus connection cable base unit via bus connected to main base unit connection Z f lt x 5 a 26 axe Does Q65WRB exit 2 Is the first extension stage Use Q65WRB in the first extension O Q65WRB stage Z 3 x fue E same EA da ate syste Bees Same Moac orman Dase ii y unit in both systems A and B c 5 and standby system 52 LIN woe OES re Remove Q4 base and replace with ono ls Q4 base connected redundant power extension base unit W D f a SOB extension base Remove Q50B and replace with
57. a Check points The control system and standby system parameter valid drive settings dip switch SW2 SW3 are checked An error occurs because the dip switch SW3 setting is incorrect Control CAIDA T j cle Tracking cable Diagram 5 16 Parameter Valid Drive Settings Consistency Check b Inconsistency Errors Table5 18 displays the consistency errors that occurred when the parameter valid drive settings are inconsistent Table5 18 Parameter Valid Drive Settings Inconsistency Errors Execution Conditions Error Description e When both systems are powered ON simultaneously The following stop error occurs in the control system When both system CPU modules are and standby system CPU modules FILE DIFF unreset RESET L CLR switch is set to the error code 6001 neutral position simultaneously e When one system starts up after the other e When the separate mode is changed to the backup mode e When reconnecting the tracking cable If the FILE DIFF occurs in the standby CPU module Use the dip switches SW2 SWS of the control system and standby system CPU modules so that the settings will be consistent The fol
58. a System switching when a fault occurs in the control system In the redundant system the standby system CPU module monitors the control system operating status When the control system is in any of the following status and is not able to continue the redundant system control the standby system CPU module switches to the control system and continues the redundant system control e A stop error occurs in the control system CPU module e The control system is powered OFF e 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 the control system CPU module Diagram 5 23 System swiching operations when a control system error occurs 5 3 The System Switching Function 5 3 1 System Switching Method Normal Standby RUN Stop program RUN Execute program D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series
59. DOL aes 8 amp 2 oo W E n gt n a 28 Diagram 3 3 Connecting the Tracking cable Connector ZE 25 uw d Tighten the connector fixing screws and fix the connector to the CPU module W E n Connector screws 2 iss Flathead screwdriver ze SS Be lu W az Z Diagram 3 4 Fixing the Tracking cable Connector z rae 95 ot eC 0 zZ E Q fe ae 7 Ww a oc E 3 3 Connecting and Disconnecting a Tracking Cable 3 3 3 4 TRACKING CABLE MELSEC TA ories 3 Disconnecting a Tracking Cable a Loosen the connector fixing screws Connector screws Flathead screwdriver Diagram 3 5 How to Loosen the Connector Fixing Screws b When disconnecting the tracking cable hold the tracking cable connector and then remove it P Redundant CPU Pa TRACKING connector Connector EN Tracking cable Diagram 3 6 Disconnecting the Tracking Cable 3 3 Connecting and Disconnecting a Tracking Cable PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM M SLSEC LE series CHAPTER4 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM The standard procedure for starting up system A as the control system and system B as the standby system of a redundant system is shown in Diagram 4 1 Explanation of program and parameter creation is not provided here Mounting Modules Mount the power supply module CPU module network module and I O module
60. New Control system CPU module 2 Tracking when program run time lt tracking time Adjust Tracking data 1 END O 3 Scan time Prepare Tracking data 1 END p Control system e CPU module Standby system CPU module Run Send Receive 4 Run program 2 program fi Tracking rt Incomplete 0 Run program Adjust Tracking data 2 4 Device data for new control system CPU module Diagram 5 54 Tracking Operation Timing When Program Execution Time gt Tracking Processing Time Prepare Tracking data 2 END P 0 END O Send processing 1 5 96 5 5 Tracking Function 5 5 7 Tracking Mode Receive Prepare Tracking data 3 ME 0 C Run Run Sprogram program f 4 Tracking processing 2 x Adjust Tracking data 1 Diagram 5 55 Tracking Operation Timing When Program Execution Time lt Tracking Processing Time Adjust Tracking data 2 D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series b Tracking in Separate Mode Scan time Prepare Tracking z data 3 gt Prepare Tracking Prepare Tracking atas a data 1 data 2 Control system Run 7 Run T Run Run Run Run END END END END END O CPU module program 1 i program 2 program 3 program 4 o program 5 program 6 New Standby system E CPU module fi
61. RST M50 X8E prt nt tne renner eee n ene n een eens 32 Error processing LED OFF error code clear X52 34 RST 82 Diagram App 25 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 Changes setting value of communication protocol according to communication specifications Resets mode switching completion Clears mode switching request by clear request POINT 1 Stop all data communication before mode switching Data communication will be stopped when mode switching is performed during data communication 2 Note that station No setting change and switching to linked operation switching from linked operation to independent mode cannot be made App 36 Appendix 6 Precautions for Using Serial Communication Module APPENDICES MELSEC LA series Appendix 6 3 INPUT Instruction The following shows the device and buffer memory used in the sample program of receiving data by the nonprocedural protocol communication PROCESSING TIME FOR REDUNDANT SYSTEMS 1 VO signal Table App 25 List of I O Signal 1 0 signal Signal name Description Xn3 XnA Reception data read request ON Requesting read
62. The CPU module ERR LED is flashing when a stop error has occurred 8 1 Troubleshooting Flow 8 1 6 When System Switching has failed TROUBLESHOOTING MELSEG Fl cries 2 W oc W gt as an operation error occurred from the control YES system s system switching instruction rA Depending on the control system error 2 code confirm below and resolve the fault 2 4100 Specify a value other than 0 for a o 4120 SP CONTSW Turn ON oZ 4121 SM1592 For separate mode BDO operation Change the program to respond to SP CONTSW instructions not from the standby system but from the control system m a q oO o zZ 4 5 x fue E Confirm individual information SD16 for control system errors u cn E p55 ass TE YES aa one Change the tracking cable a orange me raong oane D a a z2 YES oF Is SD16 8 ag wW D g5 Wait for the memory copy from control system to standby system to complete n a zv YES 4 5 ZO 5E W W Pema Wait for online program change to complete 4 Zz 1 a 6 E O o A E Q fe ae n faa gt 2 8 1 Troubleshooting Flow 8 17 8 1 6 When System Switching has failed 8 18 TROUBLESHOOTING MELSEC TA ories Check operation starting from a minimum system and work your way up For modules that are not functioning contact the nearest Mitsubishi repr
63. i an U d CPU module m END 0 bo i lt c i H i F m lt 5 N Y t R A jacking hi E ew control system Reflect tracking Output eflect tracking Output i I Output Ww CPU module transfer data p transfer data Output cit I 1 I I I l i i SET Y10 SET Y10 i SET Y10 END processing END processing l END processing T Program f E i ON i i l ON l a i l 1 T Bo MO i orf ao o Ze 1 ae zS 1 l I a _ age X10 Eo i i i i i l I 7 ON i I l I A I l I Y10 of CPU j I OFF l i module H ee T g ON Z 22 External output i y OFF ge of Y10 i i i 22 3 i l O Tracking setting is set to M X and Y Diagram 7 16 Data Output is Not Reflected to New Control System CPU Module TROUBLESHOOTING 7 4 Precautions at System Switching Occurrence 7 17 PROGRAMMING CAUTIONS Mi aL 26 Q ceries When outputting the command output e g output Y start up by writing to buffer memory clear etc consider time required for 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 Response input X10 gt A gt 4 l J Output Y10 Program example Before measures HO X10 Y10 i aya aya SET Y10 M10 X10 Y10 4
64. 1 2 3 4 System A Control System System B Standby System aa jem s g m I o f all eS a fl l j ai g i cR E z m 8 8 Tracking cable Diagram 5 1 Redundant System Configuration Determination of System A and System B In a redundant system one basic system is called System A and the other System B to identify each of the two systems connected with a tracking cable Please refer to Section 5 1 1 for determination of system A and system B Control System and Standby System In a redundant system the CPU module 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 Switching Between the Control System and Standby System If a fault occurs in the control system the backup system takes over the system control and continues the operation Please refer to Section 5 3 for switching between the control system and standby system Consistency Check between Control System and Standby System
65. 1 Overview of Remote Stations In aredundant system the control system master station controls remote stations and sends receives data to from standby system master station The standby system standby master station receives data 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 Master station Standby Master station Control System Standby System System A System B T T gt Send and receive data gt gt a a a 2 a ea Z 2 m Za 5 Recive data z3 2 z3 z gel Gc fe SG I Tracking cable Remote I O Remote device Intelligent device station station station Diagram 6 25 Control of and Data Communication with Remote Stations 6 28 6 2 Redundant System Network Overview 6 2 4 CC Link 6 REDUNDANT SYSTEM NETWORKS MELSEC TE ories
66. 28 Appendix 6 Precautions for Using Serial Communication Module APPENDICES MELSEC LA series Appendix 6 1 CSET Instruction PROCESSING TIME FOR REDUNDANT SYSTEMS 1 When setting initial setting of the unit word byte of the number of send receive data and the send receive area size a Setting the unit of send receive data length The following shows the device and buffer memory used in the sample program of the send receive data length unit setting 1 VO signal APPENDICES Table App 14 List of I O Signal I O signal OH side X n 1 E Q series C24 ready ON Accessible Signal name Description of signal ON Module error occurred OFF Module being normally operated Watchdog timer error X n 1 F cy WDT error INDEX 2 Buffer memory Write 0 word unit or 1 byte unit to the following address Table App 15 List of Buffer Memory Buffer memory address hexadecimal decimal OH side 9614 150 13614 310 Word byte units designation Buffer memory name POINT Set the send receive data length unit setting before communication In addition change the setting 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 21 For the I O signal is X Y80 to X Y9F X9E X9F Write 1 in units of bytes to p I if LTOP H8 H96 K1 K1 buffer memory address 96H
67. 3 a 8 RUN Control ceo ea St db ane i Execute program system andby Tracking cable system Normal Standby RUN 5 rare System switching i Stop program System switching requested by the 2 Ethernet interface i 7v module re gt END System 2 Ethernet r switchin z ae ae 85 2O ommunication r a System A a System B Control stari Standby i 5 Control System gt gisconnection Standby System otma anhy system Control R N t Standby System Control System Stop i system Execute programi L pee 1 i TEHE LRE 2 A 4 gage ia d WEE JHB Ze 7 z Tracking cable S 5 Be Diagram 5 24 System switching operations requested by the network module re For the Ethernet interface modules only the QU71E71 100 can detect wire break EJPOINT 1 The network module system switching can only be requested from are Z o dundant system compatible MELSECNET H network module Ethernet g i interface module and PROFIBUS DP master module ga Refer to Section 2 3 for details on serial Nos of these redundant system compatible modules 2 When the network module is mounted on the extension base unit the system g switching request cannot be issued 8 5 5 a O oc E 5 3 The System Switching Function 5 35 5 3 1 System Switching Method 5 36 REDUNDANT SYSTEM FUNCTIONS MELSEC TA eries If the network module cable is disconnected the system switching may not be performed depending on the timing when
68. 40 MELSEC TA ories 8 3 6 Main Base Unit Replacement Procedure 1 Main Base Unit Replacement The control system main base unit cannot be replaced while the redundant system is running In this case switching its system to the standby system then replace that main base unit Main base unit Control system Standb a E y system l S im oooooo COU TCOL Tracking cable Replace after using GX Developer to switch over to the standby system GX Developer Diagram 8 28 System where Control System s Main Base Unit Is Replaced Perform replacement of the standby 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 Control system Van pase unit Standby system a a J ooo0 ooo0 ooo000 oo0000 o z mg a GAMILA goy I ed EES T Ll
69. 6 46 MELSEC TA ories 6 3 3 Communication when the GOT is Connected to MELSECNET H or MELSECNET 10 PLC to PLC Network Connect GOTs to a MELSECNET 10 PLC to PLC network When using the GOT in the redundant system set MNET 10 mode to Network type in Network parameter 1 GOT connection type The following shows connection type of the GOT e MELSECNET H connection PLC to PLC network e MELSECNET 10 connection PLC to PLC network GOT 1000 series GOT A900 series MELSECNET H or MELSECNET 10 PLC to PLC network MELSECNET H or MELSECNET 10 PLC to PLC network System A Control system Station No 1 Em System B Standby system Station No 2 jos maries Tracking cable Diagram 6 37 GOT Connection Method 2 Communication method a GOT1000 series The GOT can monitor the control system 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 LF GT Designer2 Version2 Screen Design Manual b GOT A900 series The GOT specifies the target communication station connected to the MELSECNET 10 PLC to PLC network by the network No and station No It is necessary to create a screen to swi
70. 6272 peT ioe 12869 Phone 420 595 691 150 Fax 381 0 18 292 24 4 5 523 962 1L 42160 Netanya Fax 420 595 691 199 INEA SR d 0 0 SERBIA Phone 972 0 9 863 08 91 MITSUBISHI ELECTRIC EUROPE BV SPAIN B TECH as CZECH REPUBLIC Karadjordjeva 12 260 Fax 972 0 9 885 2430 annn ea 76 80 Na Ostrove 84 SER 113000 Smederevo is SMUD O7 daal i CZ 58001 Havlickuv Brod Phone 381 0 26 617 163 alates mat tad Barcelona Phone 420 0 569 408 841 Fax 381 0 26 617 163 Fax 34 93 589 1579 Fax 420 0 569 408 889 CS MTrade Slovensko s r o SLOVAKIA AFRICAN REPRESENTATIVE MITSUBISHI ELECTRIC AUTOMATION ix ae ee en a CBI Ltd SOUTH AFRICA 500 Corporate Woods Parkway U Borov 69 Phone 421 0 33 Yay 42760 Private Bag 2016 Vernon Hills IL 60061 7 580 01 Havlickuv Brod Fax 421 0 33 7735 144 ZA 1600 Isando Phone 1 847 478 21 00 Phone 490 569 777 777 Waa TT Phone 27 0 11 928 2000 Fax 1 847 478 22 83 ey 0 0 Fax 27 0 11 392 2354 Fax 420 569 777 778 Stegne 11 Beijer Electronics A S DENMARK SI 1000 Ljubljana Lautruphoj 1 3 Phone 386 0 1 513 8100 DK 2750 Ballerup Fax 386 0 1 513 8170 Phone 45 0 70 26 46 46 f Fax 45 0 70 26 48 48 ue Automation AB SWEDEN Beijer Electronics Eesti OU ESTONIA SE 20124 Malmo Parnu mnt 160i Phone 46 0 40 35 86 00 EE 11317 Tallinn Fax 46 0 40 35 86 02 Phone 372 OL SM81410 ECONOTEC AG SWITZERLAND Fax 372 0 6 51 8149 Hinterdorfstr 12 Beijer Electronics OY FINLA
71. A redundant system conducts Consistency check between Systems A and B to check if the control system and standby system are consistent so that control continues without the system going down when system switching occurs Refer to Section 5 1 4 for consistency check between systems A and B 5 1 Basic Concept of Redundant System 5 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol wW no gt 2 E zZ lt z Q W a 2 Zz O oO Z u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS MELSEC TA ories 5 Operation Mode The redundant system operates in the following three modes the Backup mode for continuing the control by system switching when the control system develops an error the Separate mode for maintenance program modification replacing the module mounted on the main base unit etc without stopping control the Debug mode for enabling only one basic system to perform debugging prior to the system operation Please refer to Section 5 4 for details on operation mode 5 1 Basic Concept of Redundant System D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series
72. Continued Setting at Time of System Switching Device No Description If an error occurs in the redundancy system error check the following corresponding bits turn ON If the error is later cancelled the bits turn OFF Each Bit Bits b15 b2 bi b0 0 OFF SD1600 0 Fixed 1 ON eee cable loose or damaged ___ Powered down reset watchdog timer hardware fault in the other system Other system stop error System Fault excluding watchdog timer O O Information sron Unable to communicate with other system Communication error is due to one of the following Tracking hardware fault Watchdog timer error has occurred in this system Unable to recognize other system due to other system fault If one of bO b1 b2 and b15 turns ON the others will turn OFF e In Debug Mode bO b1 b2 and b15 are all OFF Stores system switching condition Stores system switching condition in SD1601 on both systems at system switching SD1600 Initializes at 0 at power OFF ON reset gt reset clear The values stored in this register are as follows 0 Initial value system switching has never occurred 1 Power OFF reset hardware failure or watchdog timer error O O 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 Does not store
73. Diagram App 21 Program Example b Specification of buffer memory head address and buffer memory size used in on demand function For the specification refer to Appendix 6 6 Appendix 6 Precautions for Using Serial Communication Module App 29 APPENDICES MELSE TA series c Specification of head address area size of send area receive area The following shows the device and buffer memory used in the sample program of specifying the head address and area size 1 VO signal Table App 16 List of I O Signal I O signal X n 1 E Q series C24 ready ON Accessible ON Module error occurred OFF Module being normally operated Signal name Description Watchdog timer error X n 1 F g WDT error 2 Buffer memory Table App 17 List of Buffer Memory Buffer memory address Hexadecimal decimal CHa side Buffer memory name A24 162 1424 322 Transmission buter memory head address designation A3 4 163 1434 323 Transmission buffer memory length designation A6p 166 146 4 326 Receive purer memory head address designation A74 167 1474 327 Receive Duis memory length designation E POINT When using the following functions simultaneously be careful not to duplicate the assignment of buffer memory which stores send data and receive data dealt with the function to be used e On demand function of MC protocol e Send receive function of nonprocedural pr
74. FUNCTION LiSt cccccccccccccccccccccccccccccccccccccccccceee 5 3 H Hot start mode SPOOL OO HOH OOOOHOO OOOOH OOOOH OTOH OO OOOOOOOO 5 29 I Initial start mode COCOO OOO OO OOOOH OOOOH OOOO OOO OOOOH OOOOOOO 5 28 Internal devices COCOCOO OOOO OOOOH OO OOOOH OOOOH OOOO OOOOOOOS 5 78 Interrupt from network module eseeeeeeeeeeeeeecseceee 7 12 L LED BACKUP eeeeesesesscecocccosocosscococeccsosose 5 10 5 11 CONTROL sessesseseseesescesessosessesossosesseseesos 5 7 List of Q Siries CPU modules eseeeeeeseeceecoccocese 1 2 Basic model QCP U e ssesscsccooocoococooooosooosooo 1 2 High Performance model QCPUeeesesseeeeesesoesoe 1 4 Process CPU ecccecccccccccccccccccccccccccccccccccccccs G Redundant CP Uccecccccccccccccccccccccccccccccccccces 1 9 INDEX 1 PROCESSING TIME FOR REDUNDANT SYSTEMS n Ww Q a z i a a lt M Manual system switching ocococoooooooooooo00000000000 D 937 System switching by the system switching INSt rUCtION eeccccccccccccccccccccccccccccccceccccccceses 5 38 System switching using GX Developer eeseeseee 5 37 Memory card setting status consistency check 5 22 Memory copy from control system to standby system ccooooooooooooooooooo00000000000000000000000000000 F113 Memory copy from control system to standby system using GX Developer eeeeeccceccccccccccccces 5 116 Memory copy FUNCTION ecececcccccccccccccccccccscscee 5 1 13 Memory copy precautions evcccccccccccccccc
75. MODE LED is not ONeeeccccccccccccccccccccccccccccoccccccccccocsocees S 4 When the CPU Module BACKUP LED is ON Red eseeeeeeeeceecseeoccocooecoccocccoccoccooccoeoooe 8 5 When the SYSTEM A B LED is flashing e eeeeeeeeeeeeeeseeccccoccccccococcoccocccoccoccoccocooccoosooe8 B When the System A System B CPU module RUN LED is not ONeeeseeseeseeseseeseesoesoeceeee 3 10 When System Switching has Occurred eeeeeeseeeseeeeseesseecscoococococcoccococecoccocccosscococoosee 8 12 When System Switching has failed eseeeeseeeseeeseeeccccesoecoccocccococcoccococcccsceocsocsocossooooe 8 14 When TRK INIT ERROR error code 6140 Occurred at Redundant System Startupeesss 8 19 When CONTROL SYS DOWN error code 6310 to 6312 Occurred at Redundant System Startup eeeeesesesesesecesesosocososcocococososososososccososcocscocosocososososessso B 20 When ETX CABLE ERR OCCUrS eeccecceccccccccccccccccccccccccccccccccccccccccccccsccccccoccosoocccs 3 21 When BASE LAY ERROR OCCUrS sseescceccccccocococcocooocooccocoooocooocooooocooooooooooooos000000 Z 22 When UNIT LAY DIFF OCCUrS eeessccccccccocoocococococcoococooococooooooooooooso000000000000000000000 Z 24 When CAN T SWITCH Occurs to Control System CPU Module due to Communication Error when Turning ON OFF Power Supply of CPU Module or Booting and Shutting Down Personal Computer in MELSECNET H Network System eeeesees 8 25 8 2 Error ClEar eecccccccccccocccocoooccocococooooooooooco
76. O iva E 8 TROUBLESHOOTING 8 30 MELSEC TA ories 3 Corrective Actions When LEDs Do not Return to Status Prior to Error Occurrence If error clear is performed but LEDs do not return to the status prior to the error occurrence this might indicate that multiple continuation errors have occurred simultaneously or multiple annunciators are ON The following explains the methods of checking whether multiple continuation errors have occurred simultaneously or whether multiple annunciators are ON and the method of clearing the errors a b 8 2 Error Clear Continuation Errors other than Annunciator F ON error code 9000 The error code of the latest continuation error is stored in a special register SDO D1610 If the LEDs do not return to the status prior to the error 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 Clear the latest errors and any errors that occurred simultaneously in the error history When error clear operation is performed and the error is cleared the SDO SD1610 information shows No Errors Therefore the errors that occurred simultaneously with the latest one cannot be confirmed by SDO D1610 Annunciator F ON error code 9000 Whether Annunciator F is ON error occurrence
77. Refer to the following manual for module replacement by using online module change of GX Developer Q Corresponding MELSECNET H Network System Reference Manual g Remote I O network 5 2 Refer to the manual of the intelligent function module for module replacement by using online g Q module change of GX Developer lt E POINT Intelligent function modules other than the above cannot be replaced online using fi GX Developer Sas oe When replacing these intelligent function modules power off the remote I O zok station in advance REZ 2G ange a D D TE D d 5S QF W W az Z o 6 95 act O o Zz Q O T o wW m O iva E 8 3 Replacing Module in Redundant System 8 43 8 3 7 Procedure for Replacing Module mounted on the I O Station of Redundant System 8 TROUBLESHOOTING 8 44 MELSEC TE ories 8 3 8 Replacement of Modules Mounted to Extension Base Unit A module mounted to the extension base unit can be replaced online using GX Developer during operation of the system The following shows modules where online module change hot swapping can be performed using GX Developer e I O module 1 e Intelligent function module 2 Analog module temperature input module temperature regulating module and pulse input module 1 For changing modules online hot swapping using GX Developer refer to the following manual QCPU User s Manual Hardware Design Main
78. TROUBLESHOOTING 1 2 Features 1 13 1 OVERVIEW MELSEC TA ories 3 Network Configuration Including Redundant System a MELSECNET H PLC to PLC Network and Ethernet In the case of MELSECNET H PLC to PLC network and Ethernet control standby system switching occurs and system control and network communication is continued even when a network module fails or when network cable disconnection is detected Control station Normal station OPS Normal station 3 MELSECNET H Interface Board MELSECNET H PLC to PLC network Control system Standby system Normal station Normal station Irsai ii HTE I J Tracking cable Control station Normal station OPS Normal station E MELSECNET H L Interface Board 5 i Control system Normal station a ooo noooon Communication not possible malfunction severed network cabl
79. The RUN STOP switch is set to the STOP position to write parameters T2 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 0 On The self diagnostics error that does not stop the operation other than o battery error is detected lt a The settings have been made by the parameter so that the operation is 95 continued when an error is detected 3 ERR LED Off Normal 8 Flashing An error that stops operations has been detected Automatic write to the standard ROM is completed BOOT LED is also flashing o Zz Q O T 7 Lu l a O ira E 8 1 8 TROUBLESHOOTING MELSE Eseries Table8 1 LED Names and Explanations Continued No Name Explanation On An error has been detected with the CHK instruction or annunciator F turns on 4 USER LED Off Normal Flashing Latch clear is executed On A battery error has occurred due to battery voltage drop in the CPU 5 BAT LED module or memory card Off Normal On Boot operation has started Off Boot operation has not been executed 6 BOOT LED oo j Flashing Automatic write to the standard ROM is completed The ERR LED is also flashing Indicates the operation mode i e backup mode or separate mode On Green Backup mode On Red Unable to c
80. W i gt no E Zz lt x fa Zz Q W a 7 2 O QO 2 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS MELSEC TA ories 3 When 3D1H is stored in the special register SD1595 and the special relay SM1595 is turned ON the contents of control system memory will be copied to the standby system Then the BACKUP LED of the standby system CPU module will turn ON red Control system CPU module Standby system CPU module E C C i Flashing red Q12PRHCPU Q12PRHCPU SIs MODE BACKUP MODE O BACKUP RUN CONTROL RUN ea CONTROL ERR amp SYSTEMA ERR R SYSTEMA USER SYSTEMB ON red USER SYSTEMB BAT BAT I BOOT BOOT ON red Flashing red Diagram 5 85 LED Indications during Memory Copy 2 When memory copy begins the MEM COPY EXE error code 6410 continuati error will occur in the control system CPU module and then a STANDBY SYS DOWN error code 6300 resume error will occur 3 When memory copy begins the PRG MEM CLEAR error code 6400 stop error will occur in the standby system CPU module 4 When memory copy is complete SM1597 will turn ON Then the BACKUP LED of the standby system CPU module will turn ON red Control syst
81. ci woe gE gt oo When specifying control system using MC protocol a D D z2 System switching g e activated ae u3 cw Control system Standby system colled E EARILCAa Lu 2 gt 2 Zz lt q Q Zz Q W a n 4 iva O z 2 W Zz Tracking cable Serial communication Extension cable module 0 Z o 56 22 eC When specifying control system using MC protocol o me Q 2 Diagram 6 29 Operation for Communication with Control System CPU Module by MC Protocol tt S oc 6 2 Redundant System Network Overview 6 35 6 2 5 Serial Communication Modules 6 REDUNDANT SYSTEM NETWORKS 2 When mounting to the main base unit SLSECTO series Specify the control system by MC protocol on each eternal device and perform the communication with the control system CPU module If the control system is specified by MC protocol communication with the new control system CPU module can be performed even when system switching occurs Multiplexed Remote Master Station Multiplexed Remote Sub master Station Control system Standby system Vis
82. e The following modules cannot be mounted to remote I O station e MELSECNET H network module interrupt module Web server module e Ethernet interface modules cannot make a communication using dedicated instructions interrupt pointers e mail functions or fixed buffer and do not support FTP server functions or web server functions e Intelligent function modules other than above do not support dedicated instructions or interrupt points QnHCPU Applicable Extension base units maximum 7 levels Multi CPU System N A Applicable Single CPU System Applicable Debug mode only Applicable Bus Connection N A Applicable CPU Direct Applicable Communication with the CPU module connected to 3 Applicable Connection the GOT only Computer Link N A Applicable Connection f pp i cor Ethernet Connection Applicabl Applicable Connection pplicable Ppl ae CC Link Lin Applicabl Applicable Connection pplicabie Ppl MELSECNET H Remote Station Applicable N A for extension base unit Applicable Connection Disabled Slot 1 becomes I O number 0 Mounting I O module or i ostana Enabled nenvoremocticrontalone Mount I O modules and network modules on slots 1 an later ae Applied Restriction on the F r The Ethernet interface modules and MELSECNET applicable intelligent Not applied function modules H network modules of serial No 06052 or later are applicable Programming Tool GX D
83. eol ieolaa eo 16 0z o Tracking cable ai Replace after turning OFF the GX Developer standby system power Diagram 8 29 System where Standby System s Main Base Unit Is Replaced 8 3 Replacing Module in Redundant System 8 3 6 Main Base Unit Replacement Procedure 8 TROUBLESHOOTING M al EO LAY series 2 Replacement Procedure The replacement procedure for the main base unit is indicated in Diagram 8 30 z z W Start 3 Confirming the Main Base Unit Targeted for Replacement Confirm that the main base unit to be replaced is for the standby system CONTROL LED is Ee off When replacing the control system s power supply module switch it to be the standby system 2 using GX Developer s system switching is 20 Refer to Section 5 2 regarding system switching via GX Developer Eg 28 Turn the Standby System s Power Supply OFF Disconnect the Cable m 1 Disconnect the tracking cable from the standby system CPU module lt Refer to Section 3 3 for disconnecting the tracking cable S xe isconnect the power supply cable from the standby system power supply module G isconnect the network cable from the network module E Refer to the manual of the network module for disconnecting the network cable emove the connector terminal block from the I O module isconnect the extension cable for mounting the main base unit of the standby system
84. fe E Gz 7 ee Removing Modules a g5 Remove the modules from the main base unit g ES Refer to the QCPU User s Manual Hardware Design Maintenance and Inspection for a removing modules Replacing the Main Base Unit E 1 Remove the main base unit from the control panel etc 2 2 Mount an alternative main base unit to the control panel etc zz Se ag wW D Mounting Modules TE Mount the module that was removed from the previous base unit to the new one Mount the modules to the main base unit so that they will be located the same as those of the control system a n Refer to the QCPU User s Manual Hardware Design Maintenance and Inspection for D mounting modules z9 86 Be lu W az 1 Connect the tracking cable to the standby system CPU module Refer to Section 3 3 for connecting the tracking cable 2 Connect the power supply cable to the power supply module 3 Connect the network cable to the network module g Refer to the manual of the network module for connecting the network cable o 4 Mount the terminal block connector to the I O module 5 Connect the extension cable for mounting to the main base unit of the standby system ga o zZ E eo 0 T o w m gt O E 8 3 Replacing Module in Redundant System 8 41 8 3 6 Main Base Unit Replacement Procedure 8 TROUBLESHOOTING MELSEC Eseries Turn on the Standby System s Power Supply 1 Align the po
85. in Redundant System PROGRAMMING CAUTIONS MELSEC TAY series Create the following program to turn on the USER LED of the new control system CPU module at occurrence of system switching 1 When turning on another annunciator at system switching to turn on the USER LED When tracking the annunciator create the following program to also turn on the USER LED of the new control system CPU module OVERVIEW Program example When any of the used 32 annunciators FO to F31 is on in the new control system CPU module the USER LED is turned on To turn off the USER LED turn on the USER LED off command M100 CONFIGURATION SYSTEM SMS i mo wo o g r m When K8F0 0 F2047 provided to turn on the USER LED w00 is turned on m e Tes ran When M100 turns on F2047 is turned off When M100 turns on FO to F31 are turned off After F2047 is turned off and FO to F31 are turned off M100 is turned off Us END TRACKING CABLE Diagram 7 13 Program That Turns on the USER LED after System Switching 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 REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A a When turning on the annunciators by the OUT instruction By tracking the OUT instruction execution condition the annunciators can also be turned on i
86. including repair parts is not available after production is discontinued 3 Overseas service Overseas repairs shall be accepted by Mitsubishi s local overseas FA Center Note that the repair conditions at each FA Center may differ 4 Exclusion of loss in opportunity and secondary loss from warranty liability Regardless of the gratis warranty term Mitsubishi shall not be liable for compensation of damages caused by any cause found not to be the responsibility of Mitsubishi loss in opportunity lost profits incurred to the user by Failures of Mitsubishi products special damages and secondary damages whether foreseeable or not compensation for accidents and compensation for damages to products other than Mitsubishi products replacement by the user maintenance of on site equipment start up test run and other tasks 5 Changes in product specifications The specifications given in the catalogs manuals or technical documents are subject to change without prior notice 6 Product application 1 In using the Mitsubishi MELSEC programmable logic controller the usage conditions shall be that the application will not lead to a major accident even if any problem or fault should occur in the programmable logic controller device and that backup and fail safe functions are systematically provided outside of the device for any problem or fault 2 The Mitsubishi programmable logic controller has been designed and manufactured for applications
87. oe NEN ee Nea 5 127 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol W 12 gt 2 E Zz lt a Zz Q W a 7 2 O QO 2 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 2 Redundant Group Settings Redundant group settings are made in the network parameter group settings using GX Developer Set Group or leave it block in the network module set to the lower I O No Network module redundant group settings Module No Start 1 0 No Network type Group settings When module No 3 is set in Group module No 3 becomes grouped with module No 4 tas Diagram 5 92 Network module redundant group setting Screen 3 Confirming a System Switching Request by a Network Module If a network module requests a system switching the SD1590 bit for the module No will change to 1 b15 to b11 to bi bO SD1590 0 0 1 es 0 1 0 Tna 0 CPU module is invalid as it is 2 slot module Module 1 Module on the right side of CPU module to Module 11 Module at right most end of 12 slot base Q312B The 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 Diagram 5 93 Network Module That Issued
88. the program name should also be changed in the program settings of the PLC parameter settings Table App 9 Sample Program Names Execution Program Name Processing Content Type A processing program that makes QJ61BT11N usable with redundant system CPUs CHANGE Scan y S l Make the program settings in the PLC settings so that MAIN will be executed after CHANGE MAIN Scan A CC Link control processing program Appendix 4 Sample Programs when Using CC Link App 11 PROCESSING TIME FOR REDUNDANT SYSTEMS APPENDICES INDEX APPENDICES App 12 Appendix 4 3 Devices Used in Programs MELSEC TA eries 1 CPU Module Devices Device Nos used in sample programs and their applications are shown in Table App 10 and Table App 11 Table App 10 CPU Module Devices Device Number Application Remarks SM400 Always On SM402 ON for 1 scan only after RUN SM1515 Control system judgment flag Control system SM1515 ON SM15165 OFF SM1516 Standby system judgment flag Standby system SM1515 OFF SM1516 ON SM1518 Standby system to control system switching status 7 flag Tag OFF Manual switching prohibited Enabl hing fl SM15392 nable manual system switching fag ON Manual system switching enabled FF control program execution not possible M100 Enable control program execution flag 2 prog xonu p i ON control program execution possible ie ope A OFF system sw
89. x g 4 J a 8 3 T Z xe OO Q fe Remote I O module 5 Serial communication oo SST I module D Lo 3 o oO fo Q v f D Oo 3 a re Q 2 5 g cotie P T n PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM PEA When specifying System switching standby system using Hi activated MC protocol A Multiplexed Remote Sub master Station Multiplexed Remote Master Station z iB ee Standby system Control system Je rear ez Col leolsm W n gt n rA lt fa W n 4 iva O z 2 W Zz Remote I O module MELSECNET H Remote I O network Serial communication module D 3 Q O Ea A 3 D 3 Q O ag 2 eki e Es PROGRAMMING CAUTIONS f e Whe
90. 2 O QO 2 u Memory copy to other system start SM1595 OFF flag Set ON OFF by the user W Memory copy to other system status SM1596 OF flag OS turns ON OFF 2 a Z atx faves Memory copy to other system SM1597 OFF 5s completion flag OS turns ON wy Memory copy target I O No SD1595 0 Set by the user Memory copy status set by OS SD1596 Z 1 9 Diagram 5 89 Memory Copy Special Relay and Special Register Status Se If any of the following malfunctions occur during memory copy from the control system to the ES standby system memory copy will stop If this happens the Memory copy to other system status flag SM1596 will turn OFF and the Memory copy to other system completion flag SM1597 will turn ON Standby system power OFF 2 Standby system CPU reset 8 Tracking cable disconnection or malfunction Arh z oc E 5 7 Memory Copy From Control System To Standby System 5 121 D REDUNDANT SYSTEM FUNCTIONS 5 122 E POINT 1 MELSEC TA ories When the special relay Memory copy to other system status executed flag SM1596 or the Memory copy to other system completion 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 SM15
91. 2 Remote Operation for Redundant System In the redundant system the following remote operations can be performed by GX Developer or other means The remote operation for the Redundant CPU can be executed regardless of the communication route e Remote RUN e Remote STOP e Remote PAUSE e Remote latch clear e Remote reset The remote operation for the Redundant CPU can be executed in any of the following methods e Remote operation from GX Developer e MELSECNET H module dedicated instruction e Remote operation by MC protocol e Remote operation function from OPS using EZSocket OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE 1 Target CPU modules of remote operation a In the backup 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 REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A 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 Ol b In the separate mode Remote operation can be performed for only the CPU module of the system specified in the Connection Setup of GX Developer or other means Lu i gt no E zZ lt Zz Q W a 2 Z O O Z u 2 Remote RUN Remote STOP Remote PAUSE Remote Latch Clear
92. 2 SYSTEM CONFIGURATION 2 3 4 MELSEC TA series Restrictions on use of extension base units The I O module used by the network module or system A system B CPU module independently can be mounted to the main base unit where the Redundant CPU is mounted Mount the I O module or intelligent function module used to control the redundant system on the MELSECNET H remote I O station or the extension base unit In addition mounting the CC Link master local module on the main base unit or the extension base unit allows to use the remote I O station remote device station and intelligent device station Modules that can be mounted on a main base unit The I O modules used independently by the network module and System A or System B CPU module can be mounted on the same main base unit as a redundant CPU is mounted I O modules and intelligent function modules used to control a redundant system must be mounted on MELSECNET H remote I O stations Remote I O stations remote device stations and intelligent device stations can be used by mounting CC Link master local modules on a main base unit Modules where the number of mountable modules is restricted The module where the number of mountable modules is restricted when the redundant CPU is used is shown in Table2 3 Table2 4 Number of modules loaded Limitation of installable modules per Applicable Module Type T e QJ71LP21 25 MELSECNET H network e QU71LP21S 25 Up
93. 3 Redundant Power Supply Replacement Procedure 8 TROUBLESHOOTING MELSEC TE ories 8 3 4 I O Module Replacement Procedure 1 2 POINT Module Replacement during Power OFF When replacing the control system I O module switch its system to standby system power off the standby system and then start the replacement operation System switching is not necessary when replacing the standby system I O module Make sure to power off the standby system before replacing the I O module The standby system can be powered off while the redundant system is running I O module Control system Standby system ma Col 60lzs Col T6Colz Gol olism eSt 16S 0s Tracking cable Replace after turning OFF the standby system power GX Developer Diagram 8 22 I O Module Replacement System during Power OFF Module Replacement during Power ON By using the online module change of GX Developer the I O module can be replaced while the redundant system is running regardless of its system i e control system or standby system I O module Control system Standby system ooo000 ooo nooo is I nooo Broom
94. 30 Device Used in the Program Device No Application Remarks X50 Read command ON Read command MO Read command acceptance ON Read command acceptance M1 Read flag ON Reading 2 W O signal Table App 31 List of I O Signal I O signal CH2 side Signal name Flash ROM read completion ON Completed Description 3 Buffer memory Table App 32 List of Buffer Memory Buffer memory address Hexadecimal decimal Flash ROM read request ON Requesting Stored value GHZ side Register read delete 0 No request 1 Registration request 24 2 H 2 instructions 2 Read request 3 Deletion request 0 No designation 3H 3 Frame No direction H 3 pae Other than 0 Frame No Registration read delete O Orma comp Ston 4H 4 2 Other than 0 Abnormal result storage completion 0 No designation Number of data bytes Other than 0 Number of 54 5 registered designation data bytes registered maximum 80 bytes 6p to 2D 6 to 45 App 40 User frame Appendix 6 Precautions for Using Serial Communication Module 0 No designation Other than 0 Registered data maximum 80 bytes MELSEC Le series APPENDICES MELSEC TAY cores The program example of reading the user registration frame is shown in Diagram App 28 For the I O signal is X Y80 to X Y9F PROCESSING TIME FOR REDUNDANT SYSTEMS o E PLS Mo Pulse outputs read command 4 p_ ke
95. 50 unit incompatible with power supply module redundant power extension base unit 45 connected ZE paa wW D GEIE po Check serial No of CPU module by system monitor of GX Developer E gt N ZO ence ZO Be s first 5 digits of serial No of NO Replace with CPU module re CPU module 09012 or later compatible with extension base unit Is error code 2013 g Hardware failure of the following modules is 2 2 suspected amp amp CPU module may have hardware failure OExtension BaSe Unii 22 cat Extension cable To Consult your local Mitsubishi representative Consult your local Mitsubishi representative explaining a detailed description of the problem explaining a detailed description of the problem Diagram 8 11 Flowchart for when BASE LAY ERROR Occurs o Zz Q O T o wW m O iva E 8 1 Troubleshooting Flow 8 23 8 1 10 When BASE LAY ERROR Occurs 8 TROUBLESHOOTING MELSEC TE ories 8 1 11 When UNIT LAY DIFF Occurs The following shows the flowchart for when UNIT LAY DIFF occurs during operation of the redundant system Error message UNIT LAY DIFF ERROR was detected Is error code 6030 YES Are module mounting constitutions of control system and standby system of redundant system the same NO Module mounting status of control system and standby system should be the same Set the mode setting
96. A Control station System B Normal station 5 204 lele a S s a29 g 5 18 g 5 Ja ole es 6 3 es 6 je ane Tracking cable a Diagram 6 12 Changing the Control Station When Adding Redundant System N 209 56 Ze S ee u3 u ez Refer to Section 2 3 for GX Developer that supports a redundant system including pairing settings 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 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 wW 2 gt no z lt q Q Zz Q W a n X faa O z 2 W Zz PROGRAMMING CAUTIONS TROUBLESHOOTING 6 2 Redundant System Network Overview 6 13 6 2 1 MELSECNET H PLC to PLC network 6 REDUNDANT SYSTEM NETWORKS Mi aL 20 fel ceries 7 Precautions for Using Redundant System in MELSECNET H PLC to PLC Network a Programming of MELSECNET H The 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 the MELSECNET H so that it will not stop controlling even when the temporary communication error is detected b Error detection by turning ON OFF other station including standby system When turning ON OFF power supply of the other s
97. CPU Diagram 6 20 In the case of Remote I O Station wo 5 2014 aqaz2a Different error time operation modes can be set to the Redundant CPU remote SE 5 Pia master station and remote I O station oo When an error fuse blown I O verify error occurs in the Redundant CPU remote master station and remote I O station the data link and output of the remote I O 2 station is determined by the combination of the error time operation mode settings of E r gt the Redundant CPU remote master station and remote I O station ae The following describes the data link and output status of the remote I O station 56 determined by the combination of the parameter settings az cw a Operation when error occurs in Redundant CPU remote master station 6 Table6 3 Operation When Error Occurs in Redundant CPU Remote Master Station m Settings of operation mode for p gt Data link operation of A me error occurrence Redundant CPU Output operation from remote z9 MELSECNET H remote I O os Redundant Remote I O control status KORSE 53 i network 25 CPU station TZ Stop Depends on the output mode Stops control Stop 3 All stations stop data link hold clear settings for error Continue Stop error 3 occurrence 0 i Stop Continues control f f Z Continue All station continue data link All stations output normally o Continue Continue error zs OF OS act O 2 Refer to the following ma
98. Control Standby Watchdog timer error S system system PE om 26 si a H nO B E E 2 6 Jl e uy Tracking cable a O Oo Z EA O lt L E E GX Developer W e lt Control STOP Reset STOP Standby Watchdog timer error woe system system aga Remote operation a Z Connection target information a O T Q Connection interface COMT lt gt PLC module E D T Target PLC Stati Host PLC type Q25PRH 2 PLC status StoP g a 5 System type Control system Operation mode Backup mode Tracking cable Operation Specify execution destination PLC Reset zi Currently specified station All stations Extract memory card Specific group Lu 2 gt 2 E Zz lt x a Zz Q W a 7 2 O QO 2 u GX Developer Diagram 5 103 Remote Reset Operation When Watchdog Timer Error Has Occurred in Standby System CPU Module REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 10 Redundant CPU Functions Restricted in Redundant System 5 139 5 10 2 Remote Operation for Redundant System D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 3 Remote reset after execution of remote operation for control system or standby system CPU module from other route When remote operation is being performed for the control system or standby system CP
99. Control system switching instruction 17 Control system switching request from GX Developer Diagram 5 22 Error details window 5 3 The System Switching Function 5 3 1 System Switching Method 5 33 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol W i gt 2 E Zz lt q Zz Q W a 7 2 O QO 2 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS a T System A Control System gt Standby System System A Control System System B Standby System System A System 2 IHE fault si ag RUN Control i i 3 Execute program system Standby Tracking cable system V Control system Error Automatic switching Stop Error has i System B 7 Aiea i aea switchin Standby System gt Begin Control aa J Control System o BE Standby 5 fault e SLE Stop Error 4 system eee B SH a p HG Tracking cable lb y J 5 34 SCTE cries 1 Automatic System Switching In automatic system switching the redundant CPU determines if a system switching is necessary and automatically switches the control system and standby system 2 types of automatic system switching are available automatic system switching when a fault occurs in the control system and system switching requested by the network module
100. DO J Sets the read request ep Ww MOV H3EB D1 J Sets the frame No to be read Q X9E X9F A l r g TO H8 H2 DO K2 J Writes read command etc SET M1 Sets read flag M1 X97 17 4 SET Y97 Turns ON the read i request signal X97 x FROM H8 H4 D2 K1 Reads result of read if read a completion signal is turned ON Z RST Y97 Turns OFF the read request signal D2 KO FROM H8 H5 D3 K1 bi pee ce of user ry D3 K2 D50 Converts the number of bytes z into the number of words 7 Add 1 to the number of read L D50 Bal 20 4 words for the odd data FROM H8 H6 D4 Kozo Reads the user registration frame RST M1 J Resets the read flag Diagram App 28 Program Example Appendix 6 Precautions for Using Serial Communication Module App 41 APPENDICES MELSE TA series Appendix 6 6 ONDEMAND Instruction The following shows the device and buffer memory used in the sample program of sending data by the on demand function 1 Device of PLC CPU Table App 33 Device Used in the Program Device No Application Remarks X50 Transmission command ON Transmission completion X60 Error reset command ON Error reset Y20 For checking normal completion ON Normal completion Y21 For checking abnormal completion ON Abnormal completion MO Transmission data set ON Transmission data set M1 On demand data set ON On dema
101. 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 MELSECNET H PLC to PLC network System B a T System A E COIs TCola re ie 5 Tracking cable Set station No 3 Set station No 2 or 4 Diagram 6 10 Station No settings for the network module Network Parameter Settings The host transmission ranges of the network modules of system A and system B must be identical by making the pairing settings 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 W Network parameters Assignment the MNET 10H network range Module No 1 Assignment method Setup common and Station inherent parameters C Points Start Monitoring time 200 10ms Parameter name Start End Total slave Tana Switch screens LB LW settings x Send range for each station Send range for each station Send range for each station Send range for each station Set station No 3 LB LW Low speed LB Low speed LW Pairing Station No we Points Stat End jr Stat End Points Stat End Points Stat End or 4 pairing 256 0000 OOFF
102. GX Developer specify the control system CPU module and make the operation mode change request MELSOFT series GX Developer 1 Cannot execute this Function when the PLC is not control system Diagram 5 37 Error Dialog Box Displayed on GX Developer 5 60 5 4 Operation Mode Change Function REDUNDANT SYSTEM FUNCTIONS MELSEC Fe caries e When the operation mode change request and the system switching request are issued simultaneously The operation mode will not be changed even after the system switching is completed If the error dialog box Diagram 5 38 appears on GX Developer after the system switching repeat the operation mode change a En a ee ee Se en IJ Riemke ape due issira sah lt EEMOrIMEr Diagram 5 38 Error Dialog Box Displayed on GX Developer e When the operation mode change request is issued to the CPU module in the debug mode If the error dialog box Diagram 5 39 appears cancel Debug Mode in the redundancy parameters lt gt Section 5 1 3 MELSOFT series GX Developer LD Cannot execute this Function when the PLC status is debug mode Diagram 5 39 Error Dialog Box Displayed on GX Developer When a hardware failure or watchdog timer error has occurred in the control system CPU module If the error dialog box Diagram 5 40 appears on GX Developer cancel the specified control system CPU error and change the operating mode E MELSOFT application Cannot communicate with PLC for
103. GX Developer communication continues via an alternate path pid sw Ze Ethernet 1 System A x System B i Control System Standby System p e giel ge s 4 E a HE if E AH B ga S 8 fo 8 H i Tracking cable i i Li Sa vin ei ty E E Diagram 6 5 Communication continuation through system switching E_ POINT Communication via a tracking cable is carried out when the 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 e When the route system s power supply is off e When the route CPU module is reset e When a watchdog timer error occurs in the route CPU module e When the connected system s power supply is off e When the connected CPU module is reset e When a watchdog timer error occurs in the connected CPU module e When the tracking cable is not connected or broken 6 1 Communication with GX Developer and PX Developer 6 1 3 Cautions on Access from GX Developer and PX Developer 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series
104. GX Developer version 8 17T or later c At redundant system startup e Check for an error of the PROFIBUS DP master module at local station error information area Un G23071 For local station error information area refer to the following manual C gt PROFIBUS DP Master Module User s Manual e When there is an error clear the error to perform system switching d Continuing each function of the PROFIBUS DP master module For precautions to continue each function of the PROFIBUS DP master module refer to the following manual lt gt PROFIBUS DP Master Module User s Manual 6 40 6 2 Redundant System Network Overview 6 2 6 PROFIBUS DP 6 REDUNDANT SYSTEM NETWORKS MELSEC LA cries 6 3 Communication between the Both Systems CPU Module and GOTs a gt ir When the GOT communicates with the standby system control system CPU module the communication target can be specified by the station No The GOT cannot specify the system control system standby system system A or system B F Table6 7 shows connection method and connectability when the GOT is used in the E redundant system For the restrictions when the GOT is used in the redundant system se Tire refer to the following manual GZ no L gt GT Designer2 Version2 Screen Design Manual Table6 7 Connection Method of GOT and its Connectability in Redundant System Connection method Connec
105. Hardware Design Maintenance and Inspection Personal Computer GX Developer Diagram 4 9 Connecting GX Developer and System A CPU Module 4 10 4 5 Confirming System A System B PROCEDURE FOR STARTING UP A REDUNDANT SAE MELSEC Kel ceries 4 7 Writing Parameters and Programs to CPU Write parameters and programs to the CPU modules of System A and System B according to 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 Write to PLC Connecting interface com1 lt gt PLC module PLC Connection Station No Host PLC type G25PRH Target memory Program memory Device memory Title File selection Device data Program Common Local Param Prog Select all Cancel all selections Close Password setup ja c Program e aN Related functions F Device comment Transfer setup COMMENT l Parameter PLC Redundant Network Remote E Device memory C MAIN Redundant operation i initial m ra jal valle Clear PLC memory Remote operation Format PLC memory Arrange PLC memory DA Ea lh Create title Total free space Free space volume volume Bytes Diagram 4 10 Write to PLC Screen 2 Selection of Write Data Click the Parameters and Programs button and select parameters and programs as Write Data
106. INDEX lt lt First 5 digits of serial No is 09011 or earlier gt gt N A System Modules for the expanded system are mounted to Configuration MELSECNET H remote 1 O station lt lt First 5 digits of serial No is 09012 or later gt gt Applicable Extension base unit Up to 7 stages e The following modules cannot be mounted Interrupt module MELSECNET H network module Ethernet interface module function version B or earlier e High speed logging is not applicable when the Web server module is used e High speed collection is not applicable when the MES interface module is used e Interrupt pointer and dedicated instruction are not applicable when the intelligent function module is used System Expansion via Extension Base Unit Applicable Extension base units maximum 7 levels 1 Q4ARCPU repeat mode results in program priority mode on QnNPRHCPU Appendix 2 Comparison of Qn H CPU and QnPRHCPU App 5 System Configuration APPENDICES MELSEC LA series Table App 3 Comparison of Qn H CPU and QnPRHCPU Continuation Item System Expansion via Extension Base Unit QnPRHCPU Restrictions for Mounting Modules on Remote I O Stations e FROM TO instructions and intelligent function module devices U G are inapplicable Intelligent function modules use REMFR REMTO instructions for buffer memory access Set the remote I O station intelligent function module using GX Configurator 2
107. K1 Jlo Data sent normally Other than 0 Data not sent normally due X80 to error occurrence 59 RST 80 Cancels send request X81 X60 62 TO H8 HO HOFF Ki J Requests turning OFF error LED vse Y Resets stored value of on demand execution result Diagram App 29 Program Example Appendix 6 Precautions for Using Serial Communication Module App 43 APPENDICES MELSEC Le series Appendix 6 7 OUTPUT Instruction The following shows the device and buffer memory used in the sample program of sending data by the nonprocedural protocol communication 1 Device of PLC CPU Table App 36 Device Used in the Program Device No Application Remarks X50 Transmission command ON Transmission completion 2 W O signal Table App 37 List of I O Signal 1 0 signal E Signal name Description CH1 side CH2 side Transmission normal Xn0 Xn7 ON Normal completion completion Transmission abnormal Xn1 Xn8 ON Abnormal completion 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 Watchdog timer error ON Module error occurred X n 1 F 3 OFF Module being normally WDT error operated Yno Yn7 Transmission request ON Requesting transmission 3 Buffer memory Table App 38 List of Buffer Memory Buffer memory address Hexadecimal decimal Stored value 0 Norm
108. MELSEC TE ories 1 Redundant System a System Configuration A redundant system consists of two sets of power supply modules CPU modules main base units and network modules To configure a redundant system prepare two sets of systems i e mount the same model of power supply module CPU module and network module on each main base unit then connect the CPU modules of both systems with a tracking cable The connection direction connectors of the tracking cable determines which one is system A or B Section 5 1 1 If system A and system B are started up simultaneously system A becomes the control system If one of the systems is started up before the other the system started up first becomes the control system Section 5 1 2 same module name into Install a module with the the same slot System A Control System QJ71PB92V QJ71E71 QJ61BT11 QJ71LP21 Tracking cable Q12PRHCPU Q61P Diagram 2 2 Redundant System Configuration 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 use the Redundant CPU whose first 5 digits of serial No is 09012 or later a If system A and system B are started up with
109. Method 5 REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series POINT 1 Precautions When Executing the System Switching Instruction SP CONTSW instruction As the control system and standby system CPU module programs and device data are consistent when the system switching instruction is executed in the control system CPU module the system switching may be executed in the new control system CPU module too When executing the system switching instruction it is required to use the special relay Standby system to control system swiching 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 OVERVIEW CONFIGURATION SYSTEM Standby system to control system switching status flag SM1518 e eu HAET wo system switching command M1000 Mo B E SP CONTSW KI M10 TRACKING CABLE Cancel Signal When the SP CONTSW instruction M1001 cannot perform a system switch RST Mo the error completion device M10 T is set to ON Diagram 5 29 Program That Does Not Execute System Switching Instruction Again in New Control System CPU Module 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 e When the error completion device is OFF System switching is executed e When the error
110. Model Code SH 080006 13JL86 SH 080007 13JL87 SH 080009 13JL88 SH 080010 13JL89 SH 080008 13JF89 SH 080394 13JR64 SH 080572ENG 13JR84 A 15 HOW TO USE THIS MANUAL This manual explains the redundant system configuration functions com munication with external devices and troubleshooting The manual is classified roughly into three sections as shown below 1 Chapter 1 and 2 2 Chapter 3 3 Chapter 4 4 Chapter 5 5 Chapter 6 6 Chapter 7 7 Chapter 8 8 Chapter 9 Explains the redundant system overview and system configuration Explains the tracking cable specifications part names and connection method Explains starting up the redundant system Explains the redundant system functions Explains the communication between a redundant system and each network GOT and GX Developer Explains the precautions for programming in a redundant system Explains the troubleshooting methods and module replacement in a redundant system Explains the processing time of a redundant system Remark Sooo ooo occ ooo This manual does not explain the functions of power supply modules base units extension cables memory cards and batteries of CPU module For these details refer to the manual shown below lt QCPU User s Manual Hardware Design Maintenance and Inspection This manual does not explain the functions of the CPU module For these functions refer to the manual shown
111. O O Stop Error x x x x x O Tracked x Not tracked Ka 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 KS Section 5 5 3 5 5 Tracking Function 5 91 5 5 6 Tracking Execution OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol W n gt 2 E Zz lt j zZ W ve 7 2 O oO 2 5 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS MELSEC LA series 2 In Separate Mode The tracking data by system operating status in the separate mode is displayed in Table5 51 Table5 51 Tracking Data By System Operating Status Operating Status Tracking Data Control System Standby System Special Relay SFC Data oe Qontrol Internal Device Tale Ms AEN Instruction Data Register RUN O x x x x RUN e O x x x x Stop Error x x RUN O x STOP STOP PAUSE PAUSE O i i a 5 Stop Error x x x x x RUN x x x x x Stop Error Sree x x x x x Stop Error x x x x x Performs tracking x Does not perform tracking Device data Internal device refers to device set in the redundancy parameters tracking setting Section 5 5 3 Special relays and special
112. O forced ON OFF can be continued according to the forced ON OFF information registered by GX Developer before system switching Input by forced ON OFF of external I O X100 He 4t H i Control system Registration of forced ON OFF X100 ON Y120 ON Y121 0N Standby system jo MELECNETHH remote I O network GX Developer Remote 1 O station GX Developer leleluleledshelelelolefelul sa Output by forced ON OFF of external I O 5 Y120 ON WE Y121 ON System switching Input by forced ON OFF of external I O X100 ma HH New control system New standby system al a iea Output by forced ON OFF of external O Y120 0N Y 121 0N Forced ON OFF information tracked from control system CPU module Forced ON OFF information tracked from control system CPU module ujen letales Diagram 5 95 Input Output by Forced ON OFF of External I O at System Switching Occurrence 3 Operation of Input Output of which forced ON OFF information has been registered at Operation Mode Change If the operation mode is changed the forced ON OFF information before operation mode change remains Hence if the operation mode is chan
113. Programming Programming Programming QnACPU Programming Programming E p Manual Manual PID Manual Process Programming LEUEN Manual 5 Common Control Control LEUEI EI sf 09 MELSAP L Structured Text m 9 Instruction Instruction Instruction A 6 Confirmation of usage of aaa sequence instructions basic instructions application Details instructions etc z a q Confirmation of dedicated S instructions for process control Details 5 Confirmation of MELSAP3 s system configuration performance specifications Details ci functions programming 52 7 j Ta 2 debugging and error codes WS 5 Confirmation of the RZA programming method 8 z a specifications functions etc Details ae required for SFC programming of the MELSAP L type W Confirmation of the p 4 N programming method of the Details Eo structured text language 5 6 55 A wW D GEE W E n gt N E A Ax ZO Be lu W Pe ms Oo Z o 6 95 act eC zZ E Q fe ae N 5 a oc OVERVIEW MELSEC TA ories d Redundant CPU Purpose Confirmation of part names and specifications of the CPU module Table1 7 List of user s manual of redundant CPU O Redundant system O Maintenance and Inspection Program Fundamentals Multi CPU System Included in package QCPU User s Manual Hardware Design Maintenance and inspect
114. Q61P A1 a e Q61P A2 lt z S VM pa Q61P g amp SA ower Supply Module lt Q62P Q63P Q64P R Supply Module 2 ert ci edundant Power Supply Module Q64RP g 5 LIN Q12PRHCPU woe CPU Module Z Q25PRHCPU Ree QU71LP21 25 oza ane e QU71LP21S 25 MELSECNET H Network Module e QU71LP21G Function version QU71LP21GE D or later a QJ71BR11 gt QU71E71 B2 22 QO Ethernet Interface Module QJ71E71 B5 55 e QJ71E71 100 Tr Serial No first 5 digits CC Link Master Local Module QJ61BT11N 5 06052 or later s Function version D or 5 PROFIBUS DP Master Modele e QJ71PB92V 5 a later be lt Input Module QX 3 26 Q Output Module QY 3 mgm i e QH42 I O Combined Module QX48Y57 1 Applicable only when using the main base unit Q32B Q33B Q35B Q38B Q312B 2 Mountable only when the redundant power main base unit is used 3 indicates the type of input module and output module 22 4 The QJ61BT11 cannot be mounted on the same main base as the redundant CPU S 5 The serial No and function version can be confirmed on the rated plate and GX Developer s ES system monitor 6 For the restriction on the number of mountable modules of the Redundant CPU to the main base unit refer to Section 2 4 2 me rf a ee 2 3 Applicable Devices and Software 2 11 2 SYSTEM CONFIGURATION Mi al 26 Q ceries a Confirming the serial No on the rated plate The rated plate i
115. R Backup mode P z mode mode E oO At END Input from input module Execute Execute Not execute Not execute E e Refresh Output from output ao processing Execute Execute Not execute Not execute module Direct access of input I O access Executable Executable Inexecutable Inexecutable device DX At instruction w Instruction i Direct access of output a execution Executable Executable Inexecutable Inexecutable lt device DY E I O refresh instruction Executable Executable Inexecutable Inexecutable Z oO Refresh of intelligent Fas i 9 Executable Executable Inexecutable Inexecutable E function module Refresh of MELSECNET 4 4 4 4 Inexecutable Inexecutable Inexecutable Inexecutable H module W Refresh of CC Link E At END Executable Executable Inexecutable Inexecutable 5 as Refresh module woe processing Device initial value of link 5 i 504 Inexecutable Inexecutable Inexecutable Inexecutable wes direct device JLAL gr ceo Device initial value of Low intelligent function module Executable Executable Inexecutable Inexecutable 5 Access to ULAG a buffer Data link instruction Executable Executable Inexecutable Inexecutable ww ep memory Refresh instruction Executable Executable Inexecutable Inexecutable a Read write from to Z z a intelligent function Executable Executable Inexecutable PEU TN 55 i i xecu xecu aeration At insirueten module special function Inexecutable g 3 execution m
116. RWr0 RWr20 736 2E0u 20 W1000 W1013 faa Remote Register RWw RWw0 RWw20 480 1E0n 20 W1100 W1113 2 Special Relay SB SBO SB1FF SB400 SB5FF Special Register SW SWO0 SW1FF SW400 SW5FF 1 Indicates the number of transferred data that is specified in the BMOV instruction Appendix 4 Sample Programs when Using CC Link App 13 APPENDICES LLL mmm MELSEC LEY aries 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 Qn H Parameter Boot file SFC 1 0 assignment PLCname PLCsystem PLCfile PLCRAS 1 PLCRAS 2 Device Program Fixed scan a rs P MAIN CHANGE Delete File usability setting 1 0 refresh setting Acknowledge XY assignment Multiple r Default Check End Cancel Diagram App 2 Program Setting Screen App 14 Appendix 4 Sample Programs when Using CC Link 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 Redundant parameter Operation settings Tracking settings r Tracking device settings Device detail settings Internal devices include X Y and other intemal devic
117. Redundant System 8 3 10 Replacement Procedures of Extension Cable Q PROCESSING TIME FOR REDUNDANT SYSTEMS MELSEC Aeres CHAPTER9 PROCESSING TIME FOR REDUNDANT SYSTEMS SE ZZ e ofa lt 5 Ba wy W Oa Ona O Oo i 2 Lu 2 gt 12 The scan time for redundant system control system CPU modules is the total time for I O refresh 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 L gt QCPU Module User s Manual Function Explanation and Program Fundamentals APPENDICES The method for adding tracking time is explained here The time required for system switching will also be explained INDEX Q PROCESSING TIME FOR REDUNDANT SYSTEMS MELSEC LA series 9 1 Extension of Scan Time due to Tracking due to tracking Table9 1 Extension of Scam Refer to Table9 1 for the calculation of extended scan time of control system CPU module Time due to Tracking Tracking Mode Scan Time Extension Time ms Extension of Scam Time END Sequence Tra 0 Sequence Control system y Synchronized Tracking Trb l Ts Tra Trb Mode Tracking transfer process Standby system Adjust Tracking transfer data Extension of
118. Remote Sub master Station station No 0 Station station No 1 Control system Standby system a 9 BLE z al a g g E el g H B 8 B l a e e EA Tracking cable L MELSECNET H Remote I O network m iza il ag i Remote I O station Remote O station station No 2 station No 3 Multiplexed Remote Master St Multiplexed Remote Sub master Master Station station No k oR Station station No 1 station Control _ Standby Standby _ Control System System system Tracking cable Communication paot possible Sa AEn Remote I O network gt Ke I p is oe B l l Remote I O station station No 2 Output is preserved during system switching Remote I O station Output is preserved station No 3 during system switching Diagram 6 15 Output Status during System Switching 6 18 6 2 Redundant System Network Overview 6 2 2 MELSECNET H Remote I O network 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series
119. Replacing Module in Redundant System 8 33 8 3 2 Power Supply Module Replacement Procedure 8 TROUBLESHOOTING 8 34 2 Replacement Procedure SCTE cries The procedure for replacing the power supply modules is shown in Diagram 8 20 Confirming the System for the Power Supply Module to be Replaced Confirm that the power supply module to be replaced is for the standby system CONTROL LED OFF When the control system power supply module is to be replaced switch it to the standby system using GX Developer Refer to Section 5 2 for system switching using GX Developer Turn the Standby System Power Supply OFF l Removing the wiring Disconnect the power supply cable from the standby system power supply module l 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 for removing mounting the power supply module l Connect the power supply cable to the power supply module l Power ON the Standby System 1 Confirm that the RUN STOP switch of the standby system CPU module is in the same position as that of the control system CPU module 2 Confirm that the RESET L CLR switch of the control system CPU module is in the center position reset switch neutral position 3 Power on the control syst
120. SM1516 are ON or OFF Z Table5 4 Confirming SM1515 and SM1516 to Identify Control system and Standby system Z 2 go SM1515 SM1516 35 Control system ON OFF 2e Standby system OFF ON g zZ E Q fe ae o W a 2 5 1 Basic Concept of Redundant System 5 7 z 5 1 2 Determination of Control System and Standby System D REDUNDANT SYSTEM FUNCTIONS MELSE Eseries 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 A and System B then connect the tracking cable to the CPU modules and power the systems on again 5 1 Basic Concept of Redundant System 5 1 2 Determination of Control System and Standby System D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 5 1 3 Operation Mode The operation mode determines the redundant system operation methods Following a three operation modes are available w e Backup Mode Separate Mode e Debug mode Use GX Developer to switch bet
121. SYS DOWN error code 6300 continuation error will occur in the control system CPU module 96 By disabling Check standby system malfunction at the standby System Monitor settings in the a E redundant parameter operation mode settings with GX Developer the control system will not Te detect the STANDBY SYS DOWN continuation error 0 Z 2 no 22 O 0 zZ E Q fe ae N a oc E 5 1 Basic Concept of Redundant System 5 5 5 1 2 Determination of Control System and Standby System D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series b When system B starts up first Standby system Control system System A System B 1 2 show the powerup procedure Col 60s ONEINGE Ne Col 6o0 zam eot 0690s Tracking cable 2 Turn on the power for System A 1 Turn on the power for System B Diagram 5 5 Control System and Standby System when System B Starts Up First 2 When System A and System B Start Up Simultaneously 4 If system A and system B start up simultaneously system A will be the Control system and system B will be the Standby system If the system A and system B CPU modules are reset RESET L CLR switch is set to the RESET position and unreset RESET L CLR switch is set to the neutral position
122. SYSTEM FUNCTIONS MELSEC TA ories b In the separate mode 1 Operation when control system is powered off and then on control system CPU module is reset and then its RESET switch is set to neutral position When the control system is powered off the control system CPU module is reset the forced ON OFF information is all cleared The input output of which forced ON OFF has been registered all return to the status before the forced ON OFF registration However when the control system is powered off the control system CPU module is reset the master station on the MELSECNET H remote I O network changes to the sub master station Therefore the output to the remote I O station holds the status when the control system was powered off the control system CPU module was reset Table5 63 Operation When Control System Is Powered Off and Then On Control System CPU Module Is Reset and Then its RESET Switch Is Set to Neutral Position Item Module mounted on main base unit including Redundant CPU Module mounted on remote I O station After power is switched on RESET switch is set to neutral Input Device X changes according to the external input position Device X changes according to the external input When power is switched off CPU is reset The output status when the control system is powered off the control system CPU module is reset is held After power is switched on RESET switch is set to neutral position The external outp
123. Scam Time END Sequence Tra J0 Sequence Tra jo Control system Trb Tp gt Trb Ts Tra g Oo Tracking transfer process Standby system Prog ram Adjust Tracking transfer data Priority Extension of Scam Time Mode END 4 am Sequence Tra jo j Tra Control system Pai Sequence Trb Tp lt Trb Ts Tra Trb Tp a i Tracking transfer process Standby system Adjust Tracking transfer data Ts Scan Time Extension Time Tra Tracking Data Preparation Time Trb Tracking Processing Time Tp Program Execution Time a Overhead time for tracking transfer according to the right table 9 1 Extension of Scan Time due to Tracking Condition Momentary power failure time to max 40 While communication is executed via f Max 30 tracking cable When a momentary power failure or power off occurs in the standby system PROCESSING TIME FOR REDUNDANT SYSTEMS MELSEC TA series 1 Tracking Data Preparation Time Tra Tracking data preparation time is calculated as shown below SE Z2 Ea oa Zz Ba wy Ww Om On co Oo 2 W 2 gt n Tra 1 Trai Tra2 Tra3 Tra4 ms Tra Tracking Data Preparation Time Tral to Tra4 Transfer Data Processing Time Shown in 2 QO Table9 2 j a lt Table9 2 Processing Times of Tra1 to Tra4 Transfer Data Processing Time ms Time Set Using Redundant Trai Signal Flow Memory f 1 0 13x108 x Z P
124. Station Is Specified Redundant CPU Functions Restricted in Redundant System 2 Remote Operation for Redundant System D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series b Remote operation for both systems When Both systems A amp B is selected at the execution destination area on the Remote operation screen of GX Developer remote operation is performed for the g jam control system and standby system z Remote operation for Both systems 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 operat
125. Step 2 to 19 APPENDICES END Diagram App 12 Sample program overview flow 2 Sample program x lt Ww a zZ SM402 a SET mo f Set enable control program execute flag to ON X40 X4F X41 SB47B z 2 4 1 f l v Me no M4531 When CC Link is operating as master i station and data link is properly executed No Was8 set M4531 to ON M100 Dg rm a er germane Rater Noein fare a E S E DNR hy Fa Ne yey Nn ae oe 1 l Li i i Creates the CC Link control program Control CC Link i j ea EEE A A ENEE AEN 19 MCR No 20 END Diagram App 13 A sample program of MAIN Appendix 4 Sample Programs when Using CC Link App 23 APPENDICES MELSE TA ories Appendix 5 Method for Starting up the Previous Control System When both systems are simultaneously powered on or when the reset switches of both system CPU modules are simultaneously set to neutral position in a redundant system the redundant system will start up with system A as the control system Even when the power supplies for both systems go off temporarily due to a power failure while system B is operating as the control system system A will start up as the control system when the power supplies of both systems are turned ON In order to start up with the previous control system i e system B as the control system in this condition create the following program Diagram App 14 that uses the special relay Previous contro
126. System Standby System Operating Stop Error Switching System y A Watchdog G Switching Status Other Than Hardware Power OFF requested Switching Timer Error 5 with System ET ale Lore Failure Reset by the Using GX Switchin Timer Errors Network Developer g Instruction Module Normal x x x x x O O Continuation Error x x x x x O O Power OFF Resetting x Xx x x x x x Hardware Failure Watchdog Timer Error x x x x x x x Stop Error Other Than Watchdog Timer Errors 5 5 7 i i At network fault detection x x x x x O O Copying memory from Control System to Standby System j x x x 7 E x During Online Program Change x x x x x O O Operating Status Inconsistency x x x x XV O O Tracking Cable Disconnection x x x x x x Preparing for Tracking x x x x x x System Switching Request i x x x x x x x Timeout Executing System Switching x x x x x x x Indicates system switching possible x Indicates system switching not possible 1 Standby system Operating status is displayed in Table5 34 5 48 5 3 The System Switching Function 5 3 3 System Switching Execution Possibility D REDUNDANT SYSTEM FUNCTIONS MELSEC LA series Table5 34 Operating Status and Details Operatin p g Description ii Status z W Neral The CPU module is in the RUN STOP or PAUSE status where no error such as a continuation error or 3 stop error has occurred Continuation a f Error The CPU module is in the RUN STOP and PAUSE s
127. System Configuration 2 SYSTEM CONFIGURATION MELSEG Fl cries 6 Communications through the PROFIBUS DP a I O data exchange The PROFIBUS DP master module exchanges I O data with slave stations connected to the PROFIBUS DP N OVERVIEW b Communication method and operation at system switching of the PROFIBUS 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 z O z ira 3 9 iE Z Q oO manual wW L gt PROFIBUS DP Master Module User s Manual a i oO Control Master Standby Master Z oO x System A Control System System B Standby System fe E gt 3 gt aea q y y q a 3 amp JalE al 3 8 Elg E ajaja g E SOc o gt a Ko gt ie gt oa N o gt E prn roi o 2 z 0 e o 2 2 0 iis ce D 2 c O O a a OO 5 OaS 2 2 IEE rob o o Doct azo a ales OZA E U m ange Tracking cable W D o PROFIBUS DP A E ZE ag A wW D GEE DP Slave DP Slave DP Slave DP Slave a Diagram 2 8 Connection of Redundant System to PROFIBUS DP N ZO Ax ZO Be lu W Pe ms 0 Z 2 no z S5 cz eC 0 Z E Q fe ae N W a oc E 2 1 System Configuration 2 9 2 SYSTEM CONFIGU
128. System type Control system Operation mode Backup mode Tracking cable Operation Specify execution destination PLC Reset zl Currently specified station C All stations Specific group 7 C Extract memory card GX Developer Diagram 5 104 Remote Reset Operation after Execution of Remote STOP for Control System or Standby System CPU Module from Other Route 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 status is changed by remote operation 2 remote operation from GX Developer serial communication module is stored into b4 to b7 of SD203 5 140 5 10 Redundant CPU Functions Restricted in Redundant System 5 10 2 Remote Operation for Redundant System D REDUNDANT SYSTEM FUNCTIONS MELSEC fA series 5 11 Access to Module Mounted on Extension Base Unit F Table5 65 shows the access to a module mounted on the extension base unit when gt accessing from the control system and when accessing from the standby system z Table5 65 Access to Module Mounted on Extension Base Unit 9 Access from control system Access from standby system Execution Separate Separate timing Backup mode
129. Trace Set ROTC Rotary Table Near Path Rotation Control PTRAR Program Trace Reset RAMP Ramp Signal MSG Message Displayed on Peripheral Devices SPD Pulse Density Measurement PKEY Peripheral Device Keyboard Input PLSY Pulse Output RERD Read From Remote I O Station Special Function PWM Pulse Width Modulation Module RTO e Remote I O Station Special Function MTR Matrix Input App 4 Appendix 1 Comparison of Q4ARCPU and QnPRHCPU APPENDICES MELSEC LA series Appendix 2 Comparison of Qn H CPU and QnPRHCPU A Comparison of Qn H CPU and QnPRHCPU is shown in Table App 3 PROCESSING TIME FOR REDUNDANT SYSTEMS Table App 3 Comparison of Qn H CPU and QnPRHCPU Item QnPRHCPU QnHCPU Scan time is increased by the tracking time Periormange Sean Time Inside device 48 k word setting time _ e Synchronized tracking mode 41 ms Program priority mode 21 ms A Series Module N A Applicable lt lt First 5 digits of serial No is 09011 or earlier gt gt 11 modules Main base unit only APPENDICES Modules which are not duplicated are mounted to MELECNET H remote I O station Number of mountable modules on remote I O station 64 64 Slots Main base unit Extension base unit 7 stages Maximum Number of Modules Mounted on Main Extension Base Unit modules per station lt lt First 5 digits of serial No is 09012 or later gt gt Up to 63 modules Main base unit extension base unit 7 stages
130. Tracking Block No 58 Tracking Trigger SM1578 Tracking Block No 59 Tracking Trigger SM1579 Tracking Block No 60 Tracking Trigger SM1580 Tracking Block No 61 Tracking Trigger SM1581 Tracking Block No 62 Tracking Trigger SM1582 Tracking Block No 63 Tracking Trigger SM1583 5 90 Tracking Block No 64 Tracking Trigger 5 5 Tracking Function 5 5 5 Tracking Block And Tracking Trigger Description OFF Disable Tracking ON Enable Tracking OFF Default AG Q series Set By User or System User D REDUNDANT SYSTEM FUNCTIONS MELSEC fA series 5 5 6 Tracking Execution When a tracking trigger is turned on device data of the tracking block No that corresponds to the tracking trigger will be tracked Tracking target data is different depending on the operation mode and the operating statuses 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 Table5 50 Tracking Target Data According to Operating Statuses of Both Systems Operating Status Tracking Data Special Relay PID Control Control Syst Standby System SFC Data R ea EA teil Internal Device and Special Instruction Data Register RUN O O Q O O STOP RUN y PAUSE O O O O O Stop Error x x x x x RUN O Q O O O STOP STOP PAUSE PAUSE O O O
131. Unit 5 10 2 Remote Operation for Redundant System 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series z m This chapter explains the redundant system networks on the assumption that the a operation mode has been set to backup mode 3 6 1 Communication with GX Developer and PX Developer 6 1 1 Communication Methods with GX Developer k o The communication between GX Developer and redundant CPU module can be made DS through the following three paths e CPU module direct connection e Routing a network module wy e Routing an intelligent function module lt Oo 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 system from the following Not specified default Control system Standby system System A and System B K gt Table6 1 W Connection Setup 5 2 fo PC side I F jo Ha H i Fi a eee Serial NET 10 H NET II CC Link Ethernet in g S USB board board board board 8 T a COM COM1 Transmission speed 115 2Kbps Fe ie PLC side I F PLC MNET 10 H MNET II CC Link Ethernet jodule module module module module module PLC mode QCPU Qmode E D z2 ge Other H E Connection channel list 3 8 No specification Other station Single network Other station Co existence network PLC direct coupled setting Specify a a iz ime out Sec etry times z de
132. W p n a ag L MELSECNET H PLC to PLC network gt 35 Normal station Normal station Station No 2 ci u Station No 1 Sub control station Standbysystem Control system 6 The new control system s normal station becomes the sub control station and maintains the data link nooo oo0000 Communication E not possible l Tracking cable J Diagram 6 9 Continuation of Data Link via System Switching oii eos TC9U Lu 12 gt no Zz lt q Q Zz Q W a n X iv O z 2 W Zz PROGRAMMING CAUTIONS TROUBLESHOOTING 6 2 Redundant System Network Overview 6 11 6 2 1 MELSECNET H PLC to PLC network 6 REDUNDANT SYSTEM NETWORKS 6 12 4 5 MELSEC TE ories b Operation of New Standby System Network Module The new standby system network module that has developed a communication error is cut off from the network When the network communication error is cleared the new standby system network module is returned to the network as the normal station 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
133. a system switching request is issued to the standby system CPU module TRACKING CABLE Table5 24 Operations When a System Switching Request is issued to the standby system CPU Module System Switching Operation Mode Request System Switching by The following stop error will occur upon System Switching Not performed instruction execution OPERATION ERROR Instruction error code 4121 The following error message will be displayed on The following error message will be displayed on REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol the GX Developer that was used to perform the the GX Developer that was used to perform the Lu 2 gt no E zZ lt q Zz a W a 2 Z O O Z 5 u system switching system switching System Switching MELSOFT series GX Developer MELSOFT series GX Developer Using GX Developer e JJ Cannot execute this function when the PLC is not control system J Cannot execute this function when the PLC is not control system REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 3 The System Switching Function 5 41 5 3 1 System Switching Method D REDUNDANT SYSTEM FUNCTIONS Mi aL 20 fel ceries 5 3 2 System Switching Execution Timing Table5 25 indicates the system switching execution timing when a system switching condition occurs Table5 25 System Switching Execution Timing System pare a Reasons fo
134. are determined by which system starts up first or which RESET L CLR switch of the CPU module is set to the neutral position first F 1 When One of the Systems Starts Up Before the Other One 1 2 3 If either system A or system B starts up before the other one the system that starts up 5 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 5 2 Ww 5 a When system A starts up first 59 a OES Control system Standby system g g System A a System B Ol 1 2 show the powerup procedure Co 6 hm COLU DC OL Tracking cable Lu 2 gt no E zZ lt x a Zz Q W a 2 Zz O S Z u 1 Turn on the power for System A 2 Turn on the power for System B Diagram 5 4 Control System and Standby System when System A Starts Up First 1 Refer to Section 5 1 1 for determination of system A and system B 2 Indicates the case where one system starts up within 3 seconds after the other system a 3 If the second system does not start up within 3 seconds of the first one the STANDBY z9
135. aren AE the control system CPU module T a 2 lt ES 010a4241 gt 5 0 A mE g5 eG ange Ol W MELSOFT application ieee thio 4242H will be stored in SD1596 of J Please execute it again after confirming the state of the tracking cable e Tracking cable disconnection e Tracking cable failure the control system CPU module lt E5 010a4242 gt W 12 gt no E zZ lt Zz gt Q W a 2 Zz O O Z u The following error dialog box will appear USB cable disconnection ES MEL SOE application Cannot communicate with the PLC Execute again after checking the connections with the PLC e RS 232 cable disconnection sa E 7 5a 35 5 Precautions BF Cz a GX Developer Functions Disabled During Memory Copy The GX Developer cannot perform the following operations on either the control system or the standby system during memory copy 1 PC remote formatting Z 2 Program memory to ROM 22 3 PC write flash ROM 35 4 CPU module write during RUN said 5 System switching 6 Operation mode change 3 i 3 5 7 Memory Copy From Control System To Standby System 5 123 D REDUNDANT SYSTEM FUNCTIONS Mi aL 20 fel ceries b Restrictions on Memory Copy Memory copy cannot be done using either GX Developer or the special relays and special registers under the conditions shown in Table5 60 Table5 60 Restrictions on Memory Copy Memory Copy Operati
136. completion device is ON System switching is not executed REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol W 2 gt no E zZ lt x a Zz gt Q W a 2 Zz O O Z u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 3 The System Switching Function 5 39 5 3 1 System Switching Method D REDUNDANT SYSTEM FUNCTIONS MELSEC TE ories 2 Reasons for system switching can be set as system switching instruction parameter M1000 Mo H SP CONTSSW KI M10 Argument Reason for system switching etc Diagram 5 30 Example of System Switching Instruction programming The system switching instruction parameter value can be confirmed in the system switching instruction error details window which can be displayed from the PLC Diagnostics screen The system switching instruction parameter value can be used in troubleshooting Error details Common error information Individual error information Reason s for system 16 Nothing switching Reason s for system 1 switching failure Diagram 5 31 Error details window In addition this parameter value is also stored in the special register SD6 error common information and SD1602 system swiching dedicated instruction parameter 3 System Switching Priority The system switching priorities are shown in Table5 23 Table5 23 Priority of Reasons for System Switching Priority Reasons for S
137. control system and standby system CPU modules set the same memory card in each system 5 22 5 1 Basic Concept of Redundant System 5 1 4 System Consistency Check 5 REDUNDANT SYSTEM FUNCTIONS POINT 1 MELSEC Eseries The memory card setting status consistency check does not include the memory card capacity check When using memory cards of different capacities check the capacity required for the actual control 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 are powered on simultaneously or unreset RESET L CLR switch is set to the neutral position simultaneously When changing the memory card during redundant system operation set the memory card of the same type in each system 5 1 Basic Concept of Redundant System 5 23 5 1 4 System Consistency Check OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol wW no gt 2 E zZ lt z Q W a 7 2 Q oO 2 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS Mi aL 20 fel ceries 6 Parameter Valid Drive Settings Consistency Check
138. describes the programming procedures device names and other items necessary to implement SH 080316E PID control using process control instructions 13JF67 Sold separately QCPU Q Mode Programming Manual Structured Text SH 080366 This manual describes the structured text language programming methods 13JF68 Sold separately Q corresponding MELSECNET H Network System Reference Manual Remote I O network This manual describes the system configuration performance specifications and programming of SH 080124 MELSECNETHH network system Remote I O nework 13JF96 Sold separately Type MELSECNET 10 Network system PLC to PLC network Reference Manual This manual describes the system configuration performance specifications and programming of IB 66440 MELSECNET 10 network system PLC to PLC network 13JE33 Sold separately A 14 Related Manuals Manual Name Q Corresponding Serial Communication Module User s Manual Basic This manual provides an overview of the module and describes the applicable system configuration the specifications the procedures prior to operations the basic methods of communicating with the external device maintenance and inspection and the troubleshooting of the Q Corresponding Serial Communication Module Sold separately Q Corresponding Serial Communication Module User s Manual Application This manual contains information on how to perform data communication with external devices using the modul
139. flag M201 REMFR instruction execution flag M202 System switching triggered REMFR instruction re request flag M203 REMFR instruction completed flag M204 REMFR instruction abnormally completed flag 7 2 7 1 Instructions Restricted in Use for Redundant System Change the device number according to the system 2 The complete signal is not tracked even it is set for tracking PROGRAMMING CAUTIONS MELSEG Fl cries e Program example Diagram 7 2 shows a program that reads data from the intelligent function module on the remote I O station by the REMFR instruction gt jam gase k 1 s me Turns ON M202 when system switching occurs during execution S tone f r TF Tha 7 of the REMFR instruction O Ehi xt av tr er at a a as Turns ON M201 to execute the REMFR instruction when nt M200 or M202 is ON the MELSECNET H remote I O network is normal and normal communication can be made with the gt z Ree KI K0 Wi moo owo Ko nn remote I O station of Station No 10 J ay s 7 R mo ast mo Turns OFF M200 to M202 on completion of the REMFR lt instruction execution gt 20 f Rs Ro E m ve Processing at normal completion o o i i CONS Processing at abnormal completion _ 2 a Diagram 7 2 Example of REMFR instruction programming l 5 2 The instruction that includes no execution completion signal or write instruction z needs to be executed again as it is dif
140. g s Hardware Failure y Startup as control system za 3 Automatic System System System System BS System Control Standb Standb Control Do us Power OFF J 7 Startup as control system Switching System System System System Control Standby Standby Control Reseting Startup as control system System System System System wW System Switchin 4 uesti ee Control Standby Control Standby System switching will cause system B to lt q System System System System become control system S Module 5 Q System Switchin Control Standb Control Standb y Startup as standby system E Manual Using GX Developer System System System System System System Switching b ue y ane a Control Standby Control Standby Switching System Switching Startup as standby system i System System System System im Instruction c b E ae LIN woe Srs ThE T 2 gt n E Zn 56 Ze 20 O i s W E n gt N Zg ence ZO Be Llu W Pema 0 Z Zg 6 95 act O 0 zZ E Q fe ae N W a 2 5 3 The System Switching Function 5 47 z 5 3 3 System Switching Execution Possibility D REDUNDANT SYSTEM FUNCTIONS MELSEC A series 2 In Separate Mode System switching execution possibility in Separate Mode is shown in Table5 33 Table5 33 System Switching Execution Capability Control System Switching Condition Automatic System Switching Manual System Switching Sylen
141. green 8 1 Completed o Zz Q O T o wW a O iva E 8 1 Troubleshooting Flow 8 5 8 1 2 When the CPU Module BACKUP LED is ON Red 8 TROUBLESHOOTING Mi al AG Fl rics 1 Power off the standby system v Disconnect and then reconnect the tracking cable lt gt Section 3 3 Power on the standby system y Reset the error of the control system CPU module Refer to Section 8 2 Is the BACKUP LED lit green Replace the tracking cable c Section 8 3 8 Clear the control system CPU module errors gt Section 8 2 Is the BACKUP LED lit up solid green YES NO A A Replace standby system s CPU module lt gt gt Section 8 3 1 Clear the control system CPU module errors gt Section 8 2 Is the BACKUP LED lit up solid green YES 8 6 8 1 Troubleshooting Flow 8 1 2 When the CPU Module BACKUP LED is ON Red 8 TROUBLESHOOTING MELSEG LAY series 2 3 u Replace control system s CPU a module 1 gt Section 8 3 3 Clear the control system CPU module errors gt gt Section 8 2 z jag o Is the BACKUP T Be LED lit up solid gt ao green 2 z Please contact the nearest m Mitsubishi represenative reseller or y 5 branch office and explain the fault Completed symptoms g fue Diagram 8
142. gt 6l leals gt E 8 5 3 coaxial cables g 6 g 6 Refer to the following manual for the double 3 shielded coaxial cables f4 f4 lt Q Corresponding MELSECNET H a J Tracking cable Network System Reference Manual 5 Remote I O network Z 5 MELSECNET H Remote I O network z Redundantly powered Q33B Remote I O station Q38RB W v to v v v v v wo oO v a a ite v v v o oO oO 53 IN S s 5 5 3 NVJs 5 ita ir s s I3 G 3 3 con 2 15131231313 2 131313 3 121381213 3 818 2 lt R E EJE JE E IRQI EJE G FRIJETETETE EJE moe z lol l 3 313 216 213 612 242 12 S73 tae We oye 2 212 8 ye s l jajajaj 2 8 aga E a OS fo Oz z 3 crew anx Q65B Q68RB OS OS OS 2 Q a 2 2 2 2 2 2 S slalslalals SS E Ea E EE al i fe e ojojoj oO oO o jo jo fo ojo j EEIEIE bod G SC IEIS as Z IMEBBBEE I aie 12 2 2 2 Ee a 16 16 17 1 16 16 ze Ze o 20 a Ei wW D GEE Diagram 2 6 MELSECNET H Remote I O Network Configuration d Reference Manual W Refer to the following manual for modules that can be mounted on a remote I O i 2 ox station and parameter settings Em atx L gt Q Corresponding MELSECNET H Network System Reference Manual a5 Ss Remote I O network 2E 0 Z Zo E O 0 Z E Q ae N 3 a O oc E 2 1 System Configuration 2 7 2 SYSTEM CONFIGURATION Mi al 26 Q ceries 5 Communication via CC Link a Control
143. is connected online module change hot swapping cannot be zok performed to modules mounted on the main base unit REZ Oga crew Online Module Change Hot Swapping Possible oe x Online Module Change Hot Swapping not Possible because cannot be mounted on a main base unit z n Refer to the following manuals for online module change hot swapping of input 2 modules output modules and I O combined modules 22 ZS 2 S a Main base unit where Redundant CPU is mounted g5 lt QCPU User s Manual Hardware Design Maintenance and Inspection b Extension base unit lt Q Corresponding MELSECNET H Network System Reference Manual 7 Rsemote I O network Ze 86 Refer to the manual of each module for online module change hot swapping of ae analog input module analog output module temperature adjustment module and e pulse input module Z 65 TS oO Zz E Q Q ae i a O E 2 4 System Configuration Cautions 2 17 2 SYSTEM CONFIGURATION MELSEC TA ories 8 Cables applicable to coaxial bus system of MELSECNET H Remote I O Network In a coaxial bus system use double shielded coaxial cables Refer to the following manual for the double shielded coaxial cables lt Q Corresponding MELSECNET H Network System Reference Manual Remote I O network 2 18 2 4 System Configuration Cautions 3 TRACKING CABLE MELSEC LA series This chapter provides the tracking cable specifi
144. m Redundant operation z Connection target information S Connection interface COM1 lt gt PLE module Target PLC 0 Stationno Host PLC type Q25PRH PLC status RUN System type Control system Operation mode Backup mode lt x Remote operation Memory copy progress status S C System switching Memory copy progress in g is displayed in PZ C Change operation mode E o o wW a lt oO oO Select Memory copy Z S Diagram 5 78 Redundant Operation Screen T E 4 When the memory copy confirmation dialog box appears click the Yes button s This transfers the control system data to the standby system TI 2 lt A lu MELSOFT series GX Developer gz ofa eU t Execute Tot e Ol Diagram 5 79 Confirmation Dialog Box Displayed on GX Developer Then the BACKUP LED of the standby system CPU module will flash red Lu i gt no E Zz lt x a Zz Q W a 7 2 O QO 2 u Control system CPU module Standby system CPU module Flashing red Q12PRHCPU Q12PRHCPU MODE MODE a RUN RUN o ERR ERR a USER LJ USER BAT BAT Zz 2 BOOT BOOT a PA Flashing red 4 ae Cz Diagram 5 80 LED Indications during Memory Copy 3 W
145. module and the connection path can be confirmed a on the following GX Developer screen w Display information for the connected system in monitor status control system standby system and System A System B zZ e z 5 ae A O no wW a q O Oo zZ EA Q lt L E a ja Saz m H55 EO E gt Display information for the system specified in connection settings Lor control system standby system and System A System B Diagram 6 2 GX Developer Ladder Monitor Screen D ZO g ZE S ee wW D cw ez w H 2 gt 7 z lt z Ww a 2 X or O z Ww Zz PROGRAMMING CAUTIONS TROUBLESHOOTING 6 1 Communication with GX Developer and PX Developer 6 3 6 1 2 Confirming the Connection Target on GX Developer 6 REDUNDANT SYSTEM NETWORKS MELSEC TA ories 6 1 3 Cautions on Access from GX Developer and PX Developer Cautions on access from GX Developer and PX Developer are listed here 1 Cautions when the System Connected to GX Developer PX Developer and the Specified System are Different When the system for the CPU module 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 gt Table6 1 GX Developer PX Developer cannot communicate with the network module of the other system i e the system that is not co
146. occurrence in the I O assignment detailed setting of the PLC param eter dialog box Refer to the following manual for details of the I O assignment detailed setting gt QCPU User s Manual Function Explanation Program Fundamentals 9 Precautions for Using Redundant System in MELSECNET H Remote I O Network a Programming of MELSECNET H The 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 the MELSECNET H so that it will not stop controlling even when the temporary communication error is detected b Error detection by turning ON OFF other station including standby system When turning ON OFF power supply of the other station including standby system CPU module or booting and shutting down the personal computer where the MELSECNET H communication board is mounted the 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 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 SWITCH refer to Section 8 1 12 For details of the MELSECNET H network system
147. of both systems with a tracking cable Mount the I O module and intelligent function module of the redundant system to the MELSECNETHH remote I O station or extension base unit In addition the power supply module can be duplicated when using the redundant base unit 1 10 1 1 Redundant System Overview 1 OVERVIEW MELSEC TAY series Network module CPU module Power supply module OVERVIEW 1 1 1 1 1 1 1 1 1 1 1 1 Zz O z 5 ae So LS no MELSECNET H Remote I O network a oO Z xe O lt E H Redundantly powered Remote I O station i cn Pa e55 OFS eein ane Intelligent function a module 5 Output module 2 Input module 22 Redundant Power supply module z Q Diagram 1 1 Configuration Example of Redundant System g5 1 The control system indicates the system that actually controls the redundant system Section 5 1 2 z 2 The standby system indicates the backup system within a redundant system N gt Section 5 1 2 zx If an error occurs in the control system the standby system takes over the control of the 5 z redundant system re 3 Refer to Section 2 3 for details of network modules for redundant system Remark Sooo ooo 2 The redundant system described in this manual does not guarantee the Zg aye ore continuous operat
148. on or the CPU modules are unreset RESET a i eat r gt L CLR switch is set to the neutral position When detecting an error the redundant CPU develops a stop error Table5 19 Self Diagnostic at CPU Module Startup 6 lt Priority Diagnostics Description Detected Eror 23 pat i T fe 1 CPU module hardware check MAIN CPU DOWN 2 1000 to 1009 as RAM check RAM ERROR 1101 to 11 2 Redundant CPU L S vou 3 Operation circuit check OPE CIRCUIT ERR 1200 to 1202 Hardware Check 4 Tracking cable connection check TRK CABLE ERR 6120 m 5 Tracking communication system status check TRK INT ERROR 6140 a 6 Extension base unit mounting check BASE LAY ERROR 2010 to 2013 9 if For unsupported module being mounted check SP UNIT VER ERR 2151 5 8 Main base unit bus check NTROLBUS ERR 1411 1413 1416 9 Extension base unit bus check we Ore i 1418 10 Extension base unit mounting status EXT CABLE ERR 2020 11 Base assignment check SP UNIT LAY ERR 2122 2125 a E 12 Booting check BOOT ERROR 2210 2211 Sa 13 For parameters check MISSING PARA 2200 ws 5 pd 204 2100 to 2107 azo 14 Parameters and system configuration check SP UNIT LAY ERR OFS 2121 2124 2128 Qak e ane 15 Intelligent Function Module check SP UNIT DOWN 3 1401 16 RUN STOP switch status check OPE MODE DIFF 6020 5 d standb t fi tion 17 Control system and standby system configuratio UNIT LAY DIFF 6030 z check 5 Control system and standby system CPU module 18 Redundant Syste
149. or power wires or install them close to each other They should be installed 100 mm 3 94 inch or more from each other Not doing so could result in noise that would cause erroneous operation When controlling items like lamp load heater or solenoid valve using an output module large current approximately ten times greater than that present in normal circumstances may flow when the output is turned OFF to ON Take measures such as replacing the module with one having sufficient rated current Installation Precautions CAUTION Use the PLC in an environment that meets the general specifications contained in QCPU User s Manual Hardware Design Maintenance and Inspection Using this PLC in an environment outside the range of the general specifications could result in electric shock fire erroneous operation and damage to or deterioration of the product While pressing the installation lever located at the bottom of module insert the module fixing tab into the fixing hole in the base unit until it stops Then securely mount the module with the fixing hole as a supporting point Incorrect loading of the module can cause a malfunction failure or drop When using the PLC in the environment of much vibration tighten the module with a screw Tighten the screw in the specified torque range Undertightening can cause a drop short circuit or malfunction Overtightening can cause a drop short circuit or malfunction due to damage
150. 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 system switching Z o eo g Biel ET EO TROUBLESHOOTING 7 4 Precautions at System Switching Occurrence 7 19 PROGRAMMING CAUTIONS MELSEC TE ories 3 When output output Y writing to buffer memory is performed from the timer contact the timer goes into the above mentioned 2 status which leads to chattering of the output When the CPU module communicates with the module or external device using the output Y and buffer memory the program may not operate normally due to chattering of the output after system switching The operation for the case where the system switching occurs before the tracking transfer processing is completed after outputting the output Y from the timer contact is shown in Diagram 7 19 Program example Mo K10 0 TO TO 5 SET Y10 V Scan execution type program Scan execution type Prepare tracking program transfer data l 1 l 1 i Prepare tracking i Wait Wait transfer data 1 1 l l 0 END 0 7 END 0 Control system CPU module es 1 1 i j 4 i a l Send 1 Send __ 1 Send Tracking transfer
151. power supply to the power supply module installed in a control panel through a distribution terminal block Furthermore the wiring and replacement of a power supply module have to be performed by a maintenance worker who acquainted with shock protection QCPU User s Manual Hardware Design Maintenance and Inspection Startup and Maintenance precautions Do not touch the terminals while power is on Doing so could cause shock or erroneous operation Correctly connect the battery Also do not charge disassemble heat place in fire short circuit or solder the battery Mishandling of battery can cause overheating or cracks which could result in injury and fires Switch off all phases of the externally supplied power used in the system when cleaning the module or retightening the terminal or module mounting screws Not doing so could result in electric shock Undertightening of terminal screws can cause a short circuit or malfunction Overtightening of screws can cause damages to the screws and or the module resulting in fallout short circuits or malfunction Startup and Maintenance precautions CAUTION The online operations conducted for the CPU module being operated connecting the peripheral device especially when changing data or operation status shall be conducted after the manual has been carefully read and a sufficient check of safety has been conducted Operation mistakes could cause damage or problem
152. processing 4 Tracking transfer processing i x f i Receive m 1 Receive 1 Receive i Scan execution type Scan execution type f i f i program program i i tSystem switchin Standby system CPU module sy Ne END 0 END 0 H _ S i 4 ly N iv New control system CPU module Reflect tracking Output Reflect tracking i i Output Output data transfer data transfer f 1 1 i i i l l i I OUTTO OUTTO i ouTTO OUT TO END processing END processing END processing END processing Program y i l l 1 f 1 I ON Io i 1 ot l on l Rn a a a MO l l I 1 1 ot ae l l 1 I i l ON i 1 ON l i he ee eee Coil of TO I i l i i 1 1 I I l l I l I 1 l l 1 l l i 4 ON l l ON p Contact of TO OFF i a OFF i T T I L l 1 I LON l l ON l I I i l l Y10 of CPU module OFF l l l OFF l i r 1 i f t i I I OoN O l l ON o i a ff 44 m External output of Y10 OFF l l i I 4 OFF 1 l i I i l l l l i 7 20 Diagram 7 19 Chattering Occurs to Output by Timer Contact 7 4 Precautions at System Switching Occurrence PROGRAMMING CAUTIONS MELSEG TA series When outputting the output Y or writing buffer memory to a module or external device consider time required for tracking transfer from the control system CPU module to the standby system CPU module The program example to output delaying one scan from the time up of the a timer is shown in Diagram 7 20
153. r gt Also interrupt from the module mounted on the extension base unit cannot be made 2 When system switching occurs the new control system CPU module starts counting the interrupt interval time from 0 A i W i i zal Therefore the fixed scan execution interval is increased T q as shown in Diagram lt 7 9 The maximum value for the extension time is T q when qa q GZ gt no Control system 4 New standby system S System switching activated Int tt concen Do Scan execution type a A l 5 l Program q New standby system a a O Z xe Q Standby system ATE Begin system System Switching complete E switching 5 Program t Scan execution type New control systemi alprogram O S paa i fi cn E woe Standby system New control system OF 5 OZA ZEU ane a Interrupt interval T System switching time a Period between starting scan execution type program and system switching n Diagram 7 9 Operations of Interrupts by Internal Timers at System Switching 2 209 56 Ze 2 S Ei wW D GEE W Ee n gt N a 22 oc ZO Be lu W Pema Z o eo g cet EO TROUBLESHOOTING 7 2 Cautions on Fixed scan Clocks Programs 7 11 PROGRAMMING CAUTIONS 7 12 MELSEC TA ories 5 Interrupt from Network module Execution of the interrupt program that corresponds to the interrupt factor sent from a network module varies according to the followin
154. refer to the following manual L77 Q Corresponding MELSECNET H Network System Reference Manual PLC to PLC network 6 22 6 2 Redundant System Network Overview 6 2 2 MELSECNET H Remote I O network 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series 6 2 3 Ethernet External devices use MC protocol fixed buffers random access buffers data link a instructions etc to communicate with the CPU modules of a redundant system w Partner products including EZ Socket can also communicate with them through OPS connection Refer to the following manual below for details L Q Corresponding Ethernet Interface Module User s Manual Basic 6 POINT Be re Ethernet interface module can be mounted to the main base unit or extension Be base unit Note that dedicated instructions cannot be used when it is mounted to the extension base unit When using dedicated instructions mount it to the main base l unit S xe E E ai uw o 2 r Zz oF a D a 28 TR ez wW 2 gt no z lt a z W a 9 X faa O z 2 W Zz PROGRAMMING CAUTIONS TROUBLESHOOTING 6 2 Redundant System Network Overview 6 23 6 2 3 Ethernet 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series The control system Ethernet interface module can issue a system switching request to the control system CPU module when it detects a communication error or disconnection System switching is carried out when t
155. registers refers to the automatically tracked special relay and special register Section 5 5 3 5 92 5 5 Tracking Function 5 5 6 Tracking Execution 5 REDUNDANT SYSTEM FUNCTIONS MELSEC LA cries 5 5 7 Tracking Mode Tracking mode determines processing when a new tracking request occurs before the previous tracking processing is completed If the previous tracking has been completed while the control system CPU module is executing the END processing the next tracking will be initiated There are 2 types of tracking modes e Synchronous tracking mode e Asynchronous tracking mode 1 Tracking Mode For Each Operation Mode and System Operating Status Tracking mode is determined by the operation mode and system operating status as shown in Table5 52 Table5 52 Tracking Mode by Operation Mode and System Operating Status Operating Status Operation Mode Backup Mode to Separate Separate Mode to Backu Control System Standby System Backup Mode Separate Mode p p p p Mode Mode Synchronous to Asynchronous to Synchronous i RUN f asynchronized tracking synchronized tracking mode tracking mode i 2 mode i RUN STOP PAUSE Stop Error Asynchronous to Asynchronous to Asynchronous F P RUN i Asynchronous asynchronized tracking asynchronized tracking tracking mode STOP STOP tracking mode mode mode PAUSE PAUSE Stop Error RUN STOP E Stop Error PAUSE Stop Error
156. remote master station and system B as the multiplexed remote sub master station OVERVIEW CONFIGURATION SYSTEM 1 Overview of Remote I O Stations The control system network module 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 stations even when system switching occurs TRACKING CABLE Multiplexed Remote Sub master Station Receive data from the remote I O station and send receive data with the remote master station Multiplexed Remote Master Station Control based on data received with 4 Send and receive data the remote station and receive data with the remote sub master station ee Receive data PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM System B Standby System System A Control System REDUNDANT SYSTEM FUNCTIONS ez MELSECNET H Remote I O network Lu no gt no Zz lt x Q Zz Q W a n x iva O z 2 Ww Zz PROGRAMMING CAUTIONS Remote I O station Remote I O station Remote I O station
157. simultaneously system A will be the Control system and system B will be the Standby system Control system Standby system System A a System B a collegia CoUsleoiaa E eels lolz o Tracking cable Power on both systems simultaneously Diagram 5 6 Control System and Standby System when System A and System B Start Up Simultaneously 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 seconds of the other 5 6 5 1 Basic Concept of Redundant System 5 1 2 Determination of Control System and Standby System D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 3 When Only One System Starts Up Whichever system that starts up first will be the Control system i gt Also if the control system is already on the other system will be the Standby system w when it
158. special relays are different i Special Register Some special registers are different 3 N A A compatible Special viiereaer di jairai licable Applicable Relay SM1000 and later Must be changed to a special relay applicable for pp QnPRHCPU Program A compatible Special N A Registers SD1000 and Must be changed to a special register applicable Applicable later for QnPRHCPU 3 Number of Steps Number of steps for some instructions are different gt Low speed Execution Type AR Bi P N A Applicable Program Status Latch N A Applicable Program Trace N A Applicable Simulati NA Applicabl imulation i pplicable Debug Substituted with GX Simulator Function Sequence N A Step Program Substituted with GX Simulator Applicable Execution SFC Program N A 3 Refer to the following manual for lt L gt QCPU User s Manual Hardware Settings Maintenance and Inspection Table App 2 Instructions Inapplicable for QNPRHCPU Instruction Instruction Instruction Name Instruction Name symbol symbol LED LED Display of ASCII code PR Print ASCII code LEDC LED display of Comments PRC Print Comments SLT Status Latch Set KEY Numerical Key Input SLTR Status Latch Reset UDCNT1 1 phase Input Up Down Counter STRA Sampling Trace Set UDCNT2 2 phase Input Up Down Counter STRAR Sampling Trace Reset TTMR Teaching Timer PTRAEXE P Program Trace Execution STMR Special Function Timer PTRA Program
159. starts up 5 Control system Z iji O p Z Be nZ f 58 Tracking cable Turn on the power Leave the power in OFF position Diagram 5 7 Control System when Only One System Starts Up g 4 Confirming the Control System Standby System Identify the control system and standby system by checking the CONTROL LEDs of E CPU modules Table5 3 Confirming the control system and standby system by checking the CONTROL LEDs ci Cc y CPU module LED LED status o lt 5 fan CA 295 A E Control Standby Qed MODE BACKUP LED Name cfu RUN J controL System System seals ERR SYSTEMA soe pete CONTROL BOOT Ol Refer to the following manual for details on the CPU module LED lt gt QCPU User s Manual Hardware Design Maintenance and Inspection wW gt o E zZ lt q a zZ Q W a 2 2 O Oo 2 u W D 6 The STANDBY SYS DOWN error code 6300 continuation error will occur in the control system 3 CPU module A g By disabling Check standby system malfunction at the standby System Monitor settings in the Z Q redundant parameter operation mode settings with GX Developer the control system will not D m detect the STANDBY SYS DOWN continuation error 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
160. system New standby system es switching The slot that is located on the right side of the power supply module mounted on the main base unit CPU slot oe as In the case of redundant power supply base unit it indicates the slot that is located on the right side of a pair of power supply modules A 20 1 OVERVIEW MELSEC TA series CHAPTER1 OVERVIEW This manual explains the redundant system configuration that includes redundant CPUs and relevant functions etc Please refer to the following manuals for common specifications performance functions OVERVIEW and others to QCPUs 1 Specifications and handling of QCPUs Power Supply Modules Base z Units memory Cards etc Zo m lt QCPU User s Manual Hardware Design Maintenance and Inspection 26 2 Common Functions Programs and Devices for QCPUs lt gt QCPU User s Manual Function Explanation Program Fundamentals 7 3 Z 5 x i oak wo cob aga OES ean ane a D a BO 6 Ze ag TR a D d Z EA 2 0 6 OE 22 eC 0 zZ E Q ae ri a O 1 OVERVIEW MELSEC TA eries 3 List of Q Series CPU Module manuals The Q series CPU module manuals are as shown below For details such as manual numbers refer to ABOUT MANUALS in this manual a Basic model QCPU Table1 1 List of user s manuals of basic model QCPU Purpose Confirmation of part names and specifications of the CPU mod
161. system configuration ae parameters and programs the redundant system operates normally 25 e If the control system and standby system are inconsistent in the system configuration parameters and programs an error will occur in the standby system CPU module This check is referred to as Consistency Check Between Systems A and B a lt The consistency check is executed in the following cases 9 e When both systems are powered on simultaneously 5 e When both system CPU modules are unreset RESET L CLR switch is set to the E neutral position simultaneously e During END processing by the control system CPU module E e When the tracking cable is reconnected g b met on Table5 9 shows consistency check points and Table5 10 shows execution conditions woe aza 4 Check the memory 1 Check file contents i 5 card installation status a E Program File Program File PA Program File ia Program File 5 Parameter File Parameter File NELSEG NELSEG W N Control Standby Sa system system ars Ho o 5 aah fa o e hz Ze H 8 J zo 8 20 elis e el E ajea El wd la ve TG sCO o oN ojee TTT
162. system tracking settings screen of GX Developer the rise fall instructions will be usable in the system B programs after system switching occurs Appendix 5 Method for Starting up the Previous Control System App 27 PROCESSING TIME FOR REDUNDANT SYSTEMS APPENDICES INDEX APPENDICES MELSEC LA series Appendix 6 Precautions for Using Serial Communication Module The dedicated instructions of the serial communication module for the module mounted to the extension base unit cannot be used in the redundant CPU system For the functions to communicate using the dedicated instructions create programs by using the FROM TO instruction The dedicated instruction applicable in the serial communication module and the changeability by the FROM TO instruction are shown in Table App 13 Table App 13 Serial Communication Module Dedicated Instruction List Changeability by Instruction name Function overview FROM TO Reference section instruction Sets initial setting of the unit word byte of the number of send receive f s Applicable Appendix 6 1 data and the send receive area size CSET Performs PLC CPU monitoring registration PLC monitoring cancel to use N A the PLC CPU monitoring function Clears receive data without stopping the send processing in the 7 ae pping p oe Applicable Appendix 6 1 nonprocedural protocol UINI Switches mode transmission specificati
163. term for Q02HCPU QO6HCPU Q12HCPU and Q25HCPU QnPHCPU Generic term for Q12PHCPU and Q25PHCPU QnPRHCPU Generic term for Q12PRHCPU and Q25PRHCPU Q Series Abbreviation for Mitsubishi MELSEC Q Series Programmable Logic Controller Product name for Q series compatible SW _ D5C GPPW E type GPP function software package GX Developer indicates the version For the GX Developer versions applicable for each CPU module refer to SYSTEM CONFIGURATION in this manual Abbreviation for the operation system that includes MELSOFT and EZSocket partner products Generic term for Q33B Q35B Q38B and Q312B main base units on which CPU module Q301B except QO0JCPU Q series power supply module I O module and intelligent function module can be mounted OPS Generic term for Q38RB redundant power supply base unit on which CPU module Q30 RB except Q00JCPU redundant power supply module Q series I O module and intelligent function module can be mounted Generic term for Q52B and Q55B extension base unit on which the Q Series I O and Come intelligent function module can be mounted Generic term for Q63B Q65B Q68B and Q612B extension base unit on which Q series Q60B power supply module Q series I O module and intelligent function module are mounted Other name for Q68RB redundant power supply base unit on which redundant power CEORE supply module Q series I O module and intell
164. the MODE LED is not On Relevant to the redundant power supply module 8 1 Troubleshooting Flow 8 1 1 Flow for the Case where the MODE LED is not ON 8 TROUBLESHOOTING MELSEG LAY series 8 1 2 When the CPU Module BACKUP LED is ON Red The following flow Diagram 8 4 is for the case where the BACKUP LED of the CPU a module is on red while the redundant system is running w The BACKUP LED is lit up solid red rA e z Is the standby T system s power Turn ON the standby system power ae turned ON 26 nO YES A Clearing control system CPU module errors 5 Section 8 2 z a q oO Oo Z Is the BACKUP 5 lt No LED lit up solid YES green Has standby i system s CPU NO Cancel the standby system s Ge A module reset been CPU module reset m canceled ag BES OZA oo Clearing control system CPU module errors C gt Section 8 2 W E n a Is the BACKUP BO N YE z Q LED lit up solid z 36 green 55 a5 re Te Is the standby system CPU YES J Connect GX Developer to the standby module ERR LED system CPU module and check for flashing faulty behavior using the System mi g Monitor PLC diagnostics 2 v N k NO Zg O Correct abnormal behavior of the 55 standby system s CPU module Be Clearing control system CPU module errors 37 Section 8 2 Z Zo 6 65 NO Is the BACKUP YES T3 lt 4 LED lit up solid
165. 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 network system e If the control system detects the cable disconnection first the system switching will be performed e If the standby system detects the cable disconnection first the system switching will not be performed In this case the CAN T SWITCH error code 6220 continuation error will occur in the control system CPU module System switching request Control system Standby system Error detection Other Station s system a a a ooon Gona eol Tesn leol Ne on Cole System A ystem B 2 Cable severed System A and B are standalone 1 Cable severed QnPRH system only is standalone MELSECNET H Diagram 5 25 System Switching Operation at Cable Disconnection 5 3 The System Switching Function 5 3 1 System Switching Method 5 REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 2 Manual System Switching Manual system switching means the system switching that is done
166. the dedicated instructions Do not use them to Ethernet interface module mounted to the extension base unit e Communication control FB SEND RECV e Event notification Functions applicable in GX Developer and PX Developer MELSOFT products connectable to 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 lt GX Developer Version 8 Operating Manual lt s PX Developer Version 1 Operating Manual Programming Tool Tracking device setting When tracking device setting is not set the program is executed using the value before refresh is performed at the first scan after switching systems Set the following devices at the tracking device setting e Device which performs auto refresh setting to the intelligent function module mounted on the extension base unit by GX Configurator e Device which performs auto refresh setting to the CC Link system master local module mounted on the extension base unit Availability of interrupt pointer When interrupting from the intelligent function module mounted to the extension base unit an interrupt pointer cannot be used If set CAN T EXECUTE I error code 4225 occurs at the time of start up 7 5 Precautions of Programming when Connecting Extension Base Unit 8 TROUBLESHOOTING M BLS 26 Q series
167. to 4 in total of PLC to PLC network module e QJ71LP21G and remote I O network modules e QJ71BR11 e QJ71E71 B2 Ethernet interface module QJ71E71 B5 Up to 4 units e QU71E71 100 CC Link system master local module 5 e QJ61BT11N Up to 4 units MELSECNET H network module cannot be mounted to the extension base unit System A System B configuration Set up system A and system B so that they will be configured the same If they are configured differently a stop error will occur and they will not start up 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 2 4 System Configuration Cautions 2 15 PROCEDURE FOR STARTING UP A OVERVIEW N 2 Q z 5 o iE 2 Oo oO SYSTEM TRACKING CABLE REDUNDANT SYSTEM REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 2 SYSTEM CONFIGURATION 2 16 MELSEC TA ories 6 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 YOu System A CPU 0 7 2 3 4 en Slot number System B GPU o 2 T3 Slot 0 is 0 points redundancy 0000 0000 ooo000 gooo000
168. to the control system CPU module data will be written to the control system and standby system CPU modules Diagram 5 63 shows the operation in the case of program change in ladder mode during RUN The program change in ladder mode during RUN is executed in the order 1 and 2 Control system Standby system oh Ie al colled Col 160Is CoU DC OL IGARA g 1 Execute writing during P RUN to new control CPU module 2 after completing writing to control system CPU module write to standby system CPU module Program memory Program A Program memory Program A INC DO JH o l CY1A0 4 Addition t nec D10H ce Diagram 5 63 Procedure for Writing to Control System and Standby System When Program Is Changed during CPU RUN 5 102 5 6 Writing To The Both Systems Using GX Developer 5 6 2 Program Change While CPU is Running D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 3 Tracking Execution During Online Program Change Use the special relay SM1710 Transfer tracking data during online program change z enable flag to enable or disable the tracking execution of the following control dat
169. to the extension base unit refer to the following manual OVERVIEW K QCPU User s Manual Hardware Design Maintenance and Inspection N However the following modules cannot be mounted to the extension base unit e Interrupt module e MELSECNET H network module e Ethernet interface module Function version B or earlier 2 Q z 5 o i 2 Oo oO SYSTEM Note that the following functions are not available for the module which is mounted to the extension base unit e Dedicated instruction for the intelligent function module Section 7 1 8 e High speed logging of Web server module QU71WS96 First 5 digits of serial No is 09011 or earlier e High speed collection of MES interface module QU71MES96 First 5 digits of serial No is 09011 or earlier TRACKING CABLE 3 Modules that can be mounted on a remote I O station Refer to the following manual for modules that can be mounted on MELSECNET H remote I O network remote I O station L7 Q Corresponding MELSECNET H Network System Reference Manual Remote I O network REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A 4 Applicable software packages a Applicable to redundant system GX Developer PX Developer or GX Simulater applicable to the redundant system is the one whose version is shown in Table2 2 or later version Table2 2 Software Packages applicable to Redundant System REDUNDANT SYSTEM FUNCTIONS Version Ver 8 18U Ver 1 06G Ve
170. to the neutral UNIT LAY DIFF error code 6030 or 6035 position simultaneously e When one system starts up after the other CONFIGURATION SYSTEM The following stop error will occur in the standby system CPU module only UNIT LAY DIFF error code 6030 or 6035 e When the separate mode is changed to the backup mode e When reconnecting the tracking cable If the UNIT LAY DIFF error occurs in the standby system configure the both basic systems of the control system and standby system so that they will be consistent in the followings Model and type of modules mounted in the control system and standby system main base units e Network module mode settings TRACKING CABLE PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM If a stop error occurs in the standby system CPU module the following continuation error will occur in the control system CPU module STANDBY SYS DOWN ERROR CODE 6300 Ol 4 System configuration check when using extension base unit When the extension base unit is used there are following restrictions The error description for the case where the system configuration does not meet the following conditions is shown in Table5 15 Connect the redundant type extension base unit to the first extension stage e Only one redundant type extension base unit is applicable per system e Connect IN connector IN1 and IN2 of the redundant type extension base unit to OUT connector of the
171. to the screw or module When installing extension cables be sure that the base unit and the extension module connectors are installed correctly After installation check them for looseness Poor connections could cause an input or output failure Securely load the memory card into the memory card loading connector After installation check for lifting Poor connections could cause an operation fault Completely turn off the externally supplied power used in the system before mounting or removing the module Not doing so could result in damage to the product Note that the module can be changed online while power is on in the system that uses the Redundant CPU module or on the MELSECNET H remote I O station Note that there are restrictions on the modules that can be changed online while power is on and each module has its predetermined changing procedure For details refer to Section 2 4 Do not directly touch the module s conductive parts or electronic components Touching the conductive parts could cause an operation failure or give damage to the module Wiring Precautions Completely turn off the externally supplied power used in the system when installing or placing wiring Not completely turning off all power could result in electric shock or damage to the product When turning on the power supply or operating the module after installation or wiring work be sure that the module s terminal covers are correctly
172. tracking data range into into multiple blocks l and turn the tracking trigger of each block on and off in the program 5 80 5 5 Tracking Function 5 5 3 Tracking Data D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series b Signal Flow Memory Signal flow memory records the operation execution result of each sequence a program step i e whether each sequence program step was executed or not 2 The signal flow memory information determines whether the rise fall and SCJ instructions will be executed or not 1 Default Tracking Settings By default signal flow memory is set to be not tracked 2 Changing the Tracking Setting E When signal flow memory has not been tracked the rise fall and SCJ 23 instructions may not function normally in the new control system after system GZ switching 2g In order to ensure these instructions function even if system switching occurs change the settings so that signal flow memory will be tracked This setting reduces the number of internal device points that can be tracked z at a time by 16k words xe Q POINT 1 Precautions when disabling signal flow memory from being tracked e Rise instruction PLS g P SP 0 z Even if the execution condition is changed from off to on during system F switching the rise instruction will not be executed after system switching we Fall instruction LDF ANDF ORF MEF PLF 269 If the execution condition is off during system switching the fall r i
173. tracking execution status File batch online program change redundant tracking execution status Transfer tracking data during SM1710 online program change enable flag 3 Set whether the tracking of the following data will be executed or not during online program change redundant tracking Device memory Including SM SD that will automatically execute tracking PID control command information SFC information SM1710 can be also used to set whether tracking will be executed or not while online change of multiple program blocks or batch of files is being performed to ensure consistency of both systems This SM is also transferred form control system CPU module to standby system CPU module by tracking data b Special Regesters For Online Program Change Special regesters for online program change are shownin Table5 56 Table5 56 Special Regesters For Online Program Change Number Name Waiting time for online program D1710 change standby system 1 Explanation Set in seconds the waiting time of the standby system CPU module from when online program change to the control system CPU module is completed by the online program change for redundancy function until the online program change to the standby system CPU module starts If no online program change request is issued to the standby system CPU module within the preset time after completion of the online program change to the control system CPU modul
174. unit Applicable Connection 5 Disabled Slot 1 becomes I O number 0 Mounting I O module or Mount I O modul dnetwork modul lots Enabled normae en Soto Moun modules and network modules on slots 1 and later nay Applied Restriction on the The Ethernet interface modules and MELSECNET f applicable intelligent Not applied function modules H network module of serial No 06052 or later are applicable Programming GX Developer Version 8 18U or later is applicable Version 7 or later is applicable Tool PX Developer Version 1 06G or later is applicable Version 1 00A or later is applicable Instruction restriction Instructions listed in Table App 7 are inapplicable Program Low speed Execution Type Program 2 N A Applicable MELSECNET H network system remote I O stations have a limit for the maximum number of parameters that can be set with GX Configurator as intelligent function modules The maximum number of parameter settings for initialization settings 512 The maximum number of parameter settings for automatic refresh settings 256 Appendix 3 Comparison of QNPHCPU and QnPRHCPU App 9 PROCESSING TIME FOR REDUNDANT SYSTEMS APPENDICES INDEX APPENDICES MELSEC LA cries Table App 7 Instructions Inapplicable for QNPRHCPU Instruction Instruction p Instruction Name Instruction Name Symbol Symbol
175. will occur When the CPU modules connected with the tracking cable are running in the different modes backup mode separate mode and debug mode each of them operate as shown in Table5 8 Table5 8 Operation of CPU Module Connected to CPU Module Running in Debug Mode by Tracking Cable OPERATION MODE CPU MODULE OPERATIONS CONTROL The CPU module develops the STANDBY SYS DOWN SYSTEM error code 6300 stop error BACKUP MODE OE STANDBY The CPU module develops the CONTROL SYS DOWN SYSTEM error code 6310 stop error CONTROL The CP lei he CP le in th SEPARATE MODE SYSTEM e CPU module ignores the CPU module in the debug mode STANDBY Does not detect any error SYSTEM Cancel the debug mode in the redundant parameter when using the redundancy system in the backup mode 5 14 5 1 Basic Concept of Redundant System 5 1 3 Operation Mode D REDUNDANT SYSTEM FUNCTIONS Mi aL 3G Kel ceries 5 1 4 System Consistency Check In order to continue the redundant system control after system switching the system a configurations parameters and programs of the control system and standby system must w be consistent z In the backup mode the standby system CPU module checks if the system configurations parameters and programs of both systems are consistent The redundant system 3 operates as shown below according to the check results lt e If the control system and standby system are consistent in the
176. with the control system CPU module since the remote 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 gt GT Designer2 Version2 Screen Design Manual 6 44 6 3 Communication between the Both Systems CPU Module and GOTs 6 3 1 When Connecting GOTs to a MELSECNET H Remote I O network 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series 6 3 2 When Connecting GOTs to CC Link As for the GOT connect it to the CC Link on the main base unit or CC Link on the a extension base unit or connect it to the CC Link communication module AJ65BT G4 S3 w connected to the CC Link The GOTs will work as intelligent device stations or a remote device stations depending on the CC Link communication module used Master station Standby Master s
177. 0 6 4 Precautions for Accessing Redundant CPU from Other Networks 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series 6 5 Precautions for Writing Device Data from Other Station 1 Operation When System Switching Occurs Until Tracking Is Completed When the devices of the control system CPU module where data have been written are set to within the tracking range the device data written in the control system CPU module are also tracked to the standby system CPU module However if system switching occurs due to any of the following reasons from when write of device data to the control system CPU module is completed until tracking is completed the device data written in the control system CPU module are not tracked to the standby system CPU module e Control system power off e Control system CPU module reset e Control system hardware fault e 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 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE 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 be checked by either of the following methods a Checking for system switching by verifying written device data After write of device data to the control system CPU module is completed read the wr
178. 0000 OOFF Disable 256 0100 MFF 0100 OIFF Disable 256 0200 O2FF 0200 O2FF Enable 256 0200 02FF 0200 O2FF Enable 256 0400 O4FF Disable Identical point Help Network Specify reserved station Equal assignment iaren Points aes Spennan Gis ameters Clear Check End Cancel setting Diagram 6 11 Network Parameter Settings Refer to the following manual for network parameters L7 Q Corresponding MELSECNET H Network System Reference Manual PLC to PLC Network 6 2 Redundant System Network Overview 6 2 1 MELSECNET H PLC to PLC network 6 REDUNDANT SYSTEM NETWORKS MELSEC TE ories Pairing settings can be made for the following CPU modules that can work as the control station e Redundant CPU S oc e High performance Model QCPU z e Process CPU e Basic Model QCPU Q4ARCPU When connecting a redundant system to the network that includes the CPU module F jag other than above for which control station network parameters have been set change o 1 the system A or system B of the redundant system to the control station Z no Change control station to normal station in network LA parameters Normal station Normal station Control station PE EN z lets gt l IB 3 E2 EH gt g x Q x fe Existing MELSECNET H PLC to PLC network Normal station Addition ze e 8 fi ee lt System
179. 000000000 1 6 1 1 Communication Methods with GX DevelOopEr eeeeeesssescecccccocoeccecccsccccocoosococoococoseoseseooo G 1 6 1 2 Confirming the Connection Target on GX Developer ccooooooooooooooooo000000000000000000000000000000 3 A 11 6 1 3 Cautions on Access from GX Developer and PX Developer eeseeseeseeseseecoesoecoecoecoesocsecoe G 4 6 2 Redundant System Network Overview cooooooooooooooooo0000000000000000000000000000000000000000000000000000000 fy 7 6 2 1 6 2 2 6 2 3 6 2 4 6 2 5 6 2 6 MELSECNET H PLC to PLC network sesssscescccocooocoocoooooooooooo00000000000000000000000000000000000 8 MELSECNET H Remote VO network SOC OOO OOOH OOO OOOO OOOOH OOOOH OHOH OOO OOOO SOHO OOOOH OSOO OOO OOSOSOOOOOOS 6 15 Ethernet OOO OOOO OOO OO OOO OO OOOO OOO OOOO OOO OOOO OOO OOO OOOO OOO OOOO OOO OOOO OOO OOOO OOOOH OOOOH OOOO OOO OTOH OS OOOOOODEEOOOCE 6 23 O1 r Mia CL ee oe 6 27 Serial Communication Modules POCO OOOOH OOOOH OOOO OOD OH OOO OOS OOOOH OH OO SOS OOOOH OOOO OOS OSOHOOSOOOOO OOS OOOOOS 6 34 PROFIBUS DP COC COO OOOO OOOOH OOOO OOO OOOOH OOOO OOO OOOO OOO OOOO OOO OOOO OOO OOOO OOOO OOO OOOO OOO OO OOO OOOO OOOO OOOOC 6 39 6 3 Communication between the Both Systems CPU Module and GOTS eeecseceeceececccccccccccccccceees G 4 6 3 1 6 3 2 6 3 3 6 3 4 When Connecting GOTs to a MELSECNET H Remote I O network eseeeseeesseeseeecooocsooseo0 G 43 When Connecting GOTS to CC Link eeeeseesseees
180. 0000000000000000000000000000000000 Z 1 3 3 Connecting and Disconnecting a Tracking Cable ccooooooooooooooooo00000000000000000000000000000000000000000 3 2 CHAPTER4 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM 4 1to4 14 4 1 Mounting Modules cooooooooooooooo0000000000000000000000000000000000000000000000000000000000000000000000000000000000 4 4 2 Wiring cooocooooooooooo0000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 5 4 3 Module Initial Settingsceceececccccccccccccccccccccccccccccccccoccccscccccoccocsccsccsecvesccseccccoccoesccsococcoees A 9 4 4 Confirming that the Power Supply is ON eeeeeeeeeeeeeeecececccccceccccccccccccecccccccccecececcecececeseceeeeee 9 4 5 Confirming System A System Be seeeeeeeseseessesesoccecoooocooocosososesoccocsescococecececcoesssssossssossos 4 10 4 6 Starting up Connecting GX Developer e eeeseesesesesesesssesesossococooococecococoseseocococosossessssossos A 10 4 7 Writing Parameters and Programs to CPU esreceeeeeececceccececccccccsccccccscccccscccccccccccescscsecesees A 1 4 8 Restarting System A and System BR eee 4 12 A 10 49 Error Check OOOO CO OOO OOO OOOO OOO OOOO OOO OOOO OOO OOOO OOO OOOO DOO OOOO OOO OOOO OOO OOOO OOO OO OOO OOOOH OOOO OOOOH OO OOO OOOO OOOOOOCS 4 12 4 1 0 Confirming the Control System Standby System 0000 OOO 000000000000000000000000000000000000000000000000000 4 13 4 11 Running CPU Modules COP 4 13 CHAPTERS REDUN
181. 1 in new standby system SD1601 when switching due to control system power OFF or reset Stores command parameter when switching due to SP CONTSW instruction System switching SP CONTSW instruction parameter is stored in SD1602 on both systems dedicated at system switching command D1602 is only valid when 16 System switching instruction is stored in O O parameter SD1601 SD1602 only changes during execution of system switching due to a control system switching instruction System Switching SD1601 Results SD1602 The error code from the error occurring on the other system is stored in the bin data O The error code stored in the other system CPU module SDO is stored here Other System D161 D1610 Diagnostic Error OSet Not set 5 54 5 3 The System Switching Function 5 3 5 Special Relays Registers For System Switching D REDUNDANT SYSTEM FUNCTIONS Mi aL 3G Kel ceries 5 3 6 System Switching Precautions 1 System Switching Failure If one of the following errors occurs during system switching the system switching will fail i e the new control system will not function as control system remains as standby system and be unable to continue the control of the redundant system OVERVIEW a A tracking cable error including tracking cable disconnection has occurred during system switching due to hardware failure power off or CPU module reset CONFIGURATION S
182. 113 Bwv Ene 1000 K20 Performs a refresh of RWr W1000 to W1013 APPENDICES 35 RST s400 Set CC Link forced master switching flag to OFF 35 iry Ie ser saioi J Set refresh update request signal to ON oP ajii RsT s41 J Set refresh update request signal to OFF x Ko 08638 A ET wo Set control program execution flag to ON 2 45 reno J End main routine program 46 cad set seed Set CC Link forced master switching flag to ON RST woo Set control program execution flag to OFF 50 iret End interrupt program x0 J Diagram App 7 A sample program of CHANGE Appendix 4 Sample Programs when Using CC Link App 19 APPENDICES b Sample Program Name MAIN 1 Sample program overview flow MAIN Turn the enable control program execution flag ON Step 0 to 1 Control the CC Link Step 2 to 19 END Diagram App 8 Sample program overview flow 2 Sample program H SET M100 X40 X4F X41 SB47B 2 4 t Mc NO M4531 NO M4531 M100 oia a a ee ee 1 8 i 1 i i i i Creates the CC Link control program i i i Li 5 a a a r e a a ae a a a Ee a a a E a a a a ee re ee n E 19 MCR No 29 END App 20 MELSEC TE ories 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 Diagram App 9 A sa
183. 4 BMOV 6736 WI000 K20 4 Performs a refresh of RWr W1000 to W1013 SET s592 Allows system switching by SP CONTSW SHIS18 3s4 RST 84c f Set CC Link forced master switching flag to OFF seT 4101 Set system switching execution flag to ON RST M102 Set System B first startup system switching flag to OFF SB45A B45B E 38 SET 8401 Set refresh update request signal to ON B442 SB443 7 4l RST s841 Set refresh update request signal to OFF KO swags J SET wio Set control program execute flag to ON 48 sD1601 16 H SD1602 K2 SET moo When System B has started first and a system switch has occurred sets the control program execution flag to ON M101 X41 SM1515 SM1516 B47B 55 4 H 1H af 1 f SP CONTSH K2 w202 Switches the system when System B has started first SET w102 Set System B first startup system change flag to ON 69 FeND End main routine program 141 M102 1 4 SET s400 J Set CC Link forced master switching flag to ON RST moo Set control program execution flag to OFF 14 iret 3 End interrupt program 75 END Diagram App 11 A sample program of CHANGE App 22 Appendix 4 Sample Programs when Using CC Link APPENDICES MELSEG TA series b Sample Program Name MAIN 1 Sample program overview flow MAIN PROCESSING TIME FOR REDUNDANT SYSTEMS Turn the enable control program execution flag ON Step 0 to 1 Control the CC Link
184. 4 Flow for the Case where the CPU Module BACKUP LED is ON Lit Red 1 The control system of which CPU module has been replaced might start up as the standby system g F Make sure to check the control system BACKUP LED after replacing the CPU module T a 2 2 When using the CPU module whose first 5 digits of serial No is 09012 or later refer to Sections 39 8 1 9 and 8 1 10 for the description of error detected by the standby system ra ES Pea ane W Ee n gt N 209 56 ZE S A wW D GEE W Ee n gt N ZO Ax ZO Be lu W Pe ms 0 Z Zg F 95 ot O o Zz Q O T o wW a O iva E 8 1 Troubleshooting Flow 8 7 8 1 2 When the CPU Module BACKUP LED is ON Red 8 TROUBLESHOOTING 8 1 3 When the SYSTEM A B LED is flashing SCTE cries The following flow Diagram 8 5 is for the case where the control system CPU module SYSTEM A B LED is flashing while the redundant system is running The SYSTEM A B LED is flashing Has the tracking cable been connected to the control system and standby system CPU modules Power off the standby system Connecting the tracking cable to the control system and standby system CPU modules Section 3 3 Power on the standby system Is the SYSTEM A B LED lit Is the tracking cable connector secured to the CPU module with screws Secure the tra
185. 4x103 E2 Number of Tracking Device Ranges for Index Register K6 5x103 Number of Tracking Device Ranges for Standard RAM File E3 K7 5x 10 Register Number of Tracking Device Ranges for SRAM Card File a i k8 5x 10 Register Ei Number of Blocks not Including File Register K9 1x103 F2 Number of Blocks Including Standard RAM File Register K10 25x103 F3 Number of Blocks Including SRAM Card File Register K11 2 2 The value of K11 differs depending on QNPRHCPU Serial No QnPRHCPU whose first degits of serial No is 06081 or before 120 3 x G 3 x 108 QnPRHCPU whose first degits of serial No is 06082 or later 120 x 108 3 Gis the number of clusters of the specified file register Calculate it using the following expression G file register capacity size of one cluster Round up the fractional portion of G calculated by the above expression Use the following value as the size of one cluster Q2MEM 1MBS 256 words 512 bytes Q2MEM 2MBS 512 words 1024 bytes 9 4 9 1 Extension of Scan Time due to Tracking Q PROCESSING TIME FOR REDUNDANT SYSTEMS Mi aL 3G Kel ceries 2 Tracking Processing Time Trb Tracking processing time is calculated as shown below SE Z2 Ea oa Zz Ba wy Ww Om On co Oo 2 W 2 gt 2 Trb 0 26 x 10 x N1 N2 N3 N4 ms Tr Tracking Processing Time N1 to N4 Number of data transferred for transfer data shown in Table9 4 Unit W
186. 5 Xn4 XnB Reception abnormal detection ON Abnormal detection X n 1 F Watchdog timer error ON Module error occurred WDT error OFF Module being normally operated Yni Yn8 Reception data read completion ON Data read completed 2 Buffer memory Table App 26 List of Buffer Memory INDEX Buffer memory address Hexadecimal decimal Stored value GHZ side 0 Normal completion 258 600 268 4 616 Data reception result 1 or more Abnormal completion error code Receive data count 0 No receive data 600 1536 A00 2560 Number of data for H Hl 7 1 or later Number of receive data which read is requested 6014 to 7FFy A01 to BFFy i Data received from an external Receive data 1537 to 2047 2561 to 3071 device The following shows the program example of receiving data by the nonprocedural protocol communication is shown in Diagram App 26 For the I O signal is X Y80 to X Y9F X83 X9F J 0 FROMP H8 H600 DO K1 J Reads the number of receive data FMovP DO Z0 gt Stores the number of data read to index L A register Z0 FROMP H8 H601 D1 K0ZO 7 Reads the specified number of receive data X84 X9F J 15 f FROMP H8 H258 D8000 K1 J Reads the receive error code X83 22 Y 81 Turns ON read completion signal Y 81 X84 Diagram App 26 Program Example Appendix 6 Precautions for Using Serial Communication Module App 37 APPENDICES Appendix 6 4 PUTE
187. 5 7 Checking the BACKUP LED to Confirm the Debug Mode CPU module LED LED Status CONFIGURATION SYSTEM Q12PRHCPU LED Name LED Status on BACKUP ERR CONTROL S SYSTEMA SYSTEM TRACKING CABLE Refer to the following manual for details on the CPU module LED L gt QCPU User s Manual Hardware Design Maintenance and Inspection a Setting and Canceling the Debug Mode The debug mode must be specified in the redundant parameter settings with GX Developer to operate the system in the debug mode REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A 1 Write the redundant parameter in which Start with Debug mode is set into the CPU module and power on the system again or set the RESET L CLR switch 3 of the CPU module to reset switch neutral position Then the system will start E gt up in the debug mode ou qZz System A go Control 3 Reset the CPU module 55 System 4 Debugging standalone system WS 3 sie J HE z 2 Write parameters to the 1 Debug Mode Setting 2 CPU module a 22 Select Start with Debug tome mre uar arg Ed Mode et Z g OF tee gai W W piam ic sats az GX Developer 0 Z nO 6 95 ot A Diagram 5 9 Setting of Debug Mode on Redundant Parame
188. 8 4 PROCEDURE FOR STARTING UP A REDUNDANT BLEEM MELSEC Kel ssries E POINT When switching power on again switch power on more than 5 seconds after switching power off Failure to do so may disable a normal start of the redundant system because an inrush current of higher than the specified value may flow or the tracking communication circuit in the CPU module may not be initialized OVERVIEW CONFIGURATION SYSTEM 1 Use double shielded coaxial cables when configuring a coaxial bus system on a MELSECNET H remote I O network Refer to the following manual for the double shielded coaxial cables LF Q Corresponding MELSECNET H Network System Reference Manual Remote I O network 2 When the SYSTEM A SYSTEM B LED is off and the ERR LED is flashing they indicate that the tracking cable is not connected or is faulty Connect or change the tracking cable 3 When starting the redundant system do not perform the following operations until the BACKUP LED is ON green Failure to do so may disable a normal start of the CPU module due to a stop error TRK INIT ERROR error code 6140 or CONTROL SYS DOWN error code 6310 to 6312 Section 8 1 7 Section 8 1 8 Power either system off and then on Reset either system CPU module and then set its RESET switch to the neutral position 4 Diagnostics includes PLC diagnostics network diagnostics Ethernet diagnostics and CC Link CC Link LT diagnostics
189. 96 or SM1597 if either of them is ON then execute memory copy again When a transfer target I O No other than the standby CPU module 3D1H is set to Memory copy target I O No SD1595 and memory copy is executed the Unsupported transfer target I O No error code 4248H will be stored in SD1596 In this case memory copy will not be executed 5 7 Memory Copy From Control System To Standby System D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 4 Error Occurrence During Memory Copy If any of errors listed in Table5 59 occurs during memory copy the contents of standby z system memory will be corrupted a x P gt In this case memory copy is not complete but the special relay Memory copy in process flag SM1596 will turn OFF and the Memory copy complete flag SM1597 will turn ON Remove the cause of the error and execute memory copy again gt G z 0 Table5 59 Error Occurrence During Memory Copy E i 0 Memory Copy Using Special Ne Cause Memory Copy Using GX Developer U RAN Sl Pp Relays and Special Registers The following error dialog box will appear iat Control system power OFF A a a i Cannot communicate with the PLC Execute again after checking the connections with the PLC 6 e Control system CPU reset SM es 01808201 gt g x fe ai e Standby system power OFF FS CGS aes eS A er aE 4241H will be stored in SD1596 of iF reset status O gz gt e Standby system CPU reset Deer WO
190. A N E 22 ence ZO ae Llu W Pema Begin tracking transfer oO zZ Completed 2 2 g Diagram 5 47 Tracking Execution Procedure fe 5 TS oO mS fo ae N W a ve 5 5 Tracking Function 5 77 5 5 2 Tracking Execution Procedure D REDUNDANT SYSTEM FUNCTIONS Mi aL 26 fel ceries 5 5 3 Tracking Data Tracking data are shown in Table5 43 Table5 43 Tracking Data Settings Settin i 3 Auto 9g Operating Mode Description Change by Backup Separate Tracking 2 User Mode Mode RIDEES Data of input X output Y internal relay M O 4 O O O and others used in programs Device Data turned ON and OFF by user Data Special neigy C gt Table5 46 gt m a Data stored by user gt Table5 47 O x O O Data that determines whether the rise and fall Signal Flow Memory instructions will be executed or not in x O O x sequence programs SFC data Data used to execute SFC O x O x PID Control Instruction PID control data specified by PIDINIT and data S PIDINIT instructions O O a 1 Auto tracking enabled x Auto tracking disabled 2 Setting change enabled x Setting change disabled 3 Tracking enabled x Tracking disabled 4 The device range set by default will be transferred 1 Tracking Data Range Setting by User The tracking data range and tracking timing can be set by the user This applies to the internal devices and signal fl
191. ANT SYSTEM FUNCTIONS MELSE TA ories 5 3 4 Both Systems Operations After System Switching Table5 36 and Table5 37 indicates the CPU module and network module operations after system switching is performed 1 CPU Module Operations Table5 36 Control System and Standby System CPU Module Operation After System Switching Item Initial Execution Type Program New Control System CPU Module Does not execute the program However executes the initial execution type program from the 0 step again if it was not completed in the previous control system at the time of system switching Scan Execution Type Program Executes scan execution type program based on the tracked device data from step 0 New Standby System CPU Module Program Fixed Scan Stops program execution 5 A i A Xi fon Execution Starts counting the interrupt interval time from 0 Refer to Pe prog s Execution Type Section 7 2 Program Standby Type y e Not executed Program Interrupt Executes when the interrupt factor is established Refer to Program Section 7 2 Starts reception of tracking data Tracking Starts tracking to the new standby system However stops the reception of tracking data if a stop error has occurred Online Program Change Continues the write operation after system switching Continues the write operation after system switching Online Change of Batch of Files Continues the write ope
192. CAUTIONS Section 4 2 5 5 3 7 1 7 3 8 2 Appendix 4 5 Appendix 5 Revision involving Redundant CPU serial No 09012 Addition function Q65WRB Partial Addition 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 Addition Section 8 1 9 8 1 10 8 1 11 8 3 8 8 3 10 Chapter 6 Section 6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 6 10 Chapter 7 Chapter number correction Section 8 3 8 gt 8 3 9 Japanese Manual Version SH 080474 H This manual confers no industrial property rights or any rights of any other kind nor does it confer any patent licenses Mitsubishi Electric Corporation cannot be held responsible for any problems involving industrial property rights which may occur as a result of using the contents noted in this manual 2004 MITSUBISHI ELECTRIC CORPORATION INTRODUCTION Thank you for choosing the Mitsubishi MELSEC Q Series of General Purpose Programmable Controllers Before using the equipment please read this manual carefully to develop full familiarity with the functions and performance of the Q series PLC you have purchased so as to ensure correct use CONTENTS SAFETY PRECAUTIONS eccccccc
193. CNET H Network System Reference Manual PLC to PLC network lt QnA Q4AR Corresponding MELSECNET 10 Network System Reference i Manual 3 Z0 Normal station Normal station Normal station Control station A 55 aye T T wW D SHHHE SHREE RESEHHE JESHHHEHE JEBE K s 3 3 3 2 5 2 2182 e 5 2 2 2 213 8 Ezd E k E E 7 e es o S 8 a oo ao W H n a MELSECNET H MELSECNET 10 Mode PLC to PLC network communication with other stations z9 Ax O Normal station Normal station Normal station Normal station 5 System A System B System A System B ow Control System Standby System Control System Standby System Z EJ om nen me Ey 5 Olojo O a E Z 2 no z S5 Pairing setting is required Pairing setting is required T S Diagram 2 5 Connection of Redundant System to MELSECNET H PLC to PLC Network 1 Use GX Developer Version 8 18U or later when making the pairing settings g 2 The Q4ARCPU makes pairing settings using the S PAIRSET instruction 5 2 N 2 a O oc E 2 1 System Configuration 2 5 2 SYSTEM CONFIGURATION 2 6 MELSEC TA ories 4 Communication via MELSECNET H Remote I O Network a Controlling External Devices b A redundant system controls external devices using I O modules and intelligent function modules mounted on MELSECNET H remote I O network remote I O stations Communication modules that cannot be mounted on main base units of a redun
194. CPU module Default Off Execution of standard ROM memory copy Stores the status upon completion of memory copy Stores the same value as SD1596 f Applicable to both Backed up for a power failure this register is not control system and SD952 initialized when power is switched off and then on or the System a Ki standby system CPU RESET L CLR switch is moved to the reset position and dies module then to the neutral position Special oe Rea It is initialized by latch clear operation SD1595 Store 3D1H standby system CPU module I O No into User Specific to control this relay before turning on SM1595 system CPU module This relay stores the status upon completion of memory Applicable to control copy System SD1596 system and standby 0 Completion 0 Completion system CPU modules 1 If one of the followings occurs during memory copy from control system to standby system the memory copy will be stopped In this case the Memory copy to other system status flag SM1596 turns off and the Memory copy to other system completion flag SM1597 turns on Standby system power OFF Standby system CPU module reset Tracking cable disconnection or malfunction 5 114 5 7 Memory Copy From Control System To Standby System D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series c Memory Copy Precautions 1 Before memory copy the standby system CPU memory will be automatically z formatted
195. Can t execute on standby system Communication from GX Communication specified by Communication error Developer etc control system CPU module Returns error code 4248H on startup inconsistency Cannot execute system switching ignores system switching request REDUNDANT SYSTEM NETWORKS 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 PROGRAMMING CAUTIONS 2 Monitoring the Watchdog Timer During System Switching The redundant system suspends the watchdog timer from being monitored during system switching Therefore the WDT ERROR error code 5001 will not occur in the system switching scan even if the scan time exceeds the monitoring time set in the scan time watchdog timer TROUBLESHOOTING 5 3 The System Switching Function 5 255 5 3 6 System Switching Precautions D REDUNDANT SYSTEM FUNCTIONS 5 56 MELSEC Eseries 3 Enabling System Switching During Online Program Change System switching is disabled during online program change In order to prevent system switching during online program change the redundant system disables the redundant CPU module from performing system switching prior to online program change and enables it to perform system switching upon completion of online program change I
196. D control instruction data eeeeeseeeeesseeeeececoee 5 82 Precautions when executing the SP CONTSW INSTFUCTION eecccccccccccccccccccccccccccccccccccccccccecces 5 30 Precautions when executing the system switching INSTFUCTION cecececcccccccccccccccccccccccceccee 5 30 Previous control system Cocccccccccccccccccccccccce App 24 Procedure for mounting MOAUIES seeeeeeeeeseeeeeesese 4 4 Procedure for starting up a redundant system ses 4 1 Processing LIME ec cccccccccccccccccccccccccccccccccccccccs O Program priority MOE eccceccccccccccccccccccccccccccse 5 OF Programming CAUTIONS ccecccccccccccccccccccccccccccccce 7 R Reason for system Switching ssereeeeseseeeeeeseseeees 5 33 INDEX 2 Redundant CPU operation upon an error CIRTECTION ccecccccccccccccccccccccccccccccccccccccccccccesee OF Redundant power extension base Unit eeeeeeeeeeee A 19 Redundant power main base Unit eeseeeeeeeeeeeeees A 19 Redundant system functions eeseeeeeeeeceeeeeeee D 1 5 31 System switching method ecccccccccccccccccccccceee 5 30 Redundant system OVEIVIEW cecccccccccccccccccccccce Redundant system configuration eeeeeeeesesseoe 1 11 Redundant type extension base Uniteceeeeeeeeeeeee A 19 Remote I O network eceeccecccccccccccccccccccccccccceee 5 15 Remote latch clear eeecsecccccccccccccccccccccccccvcces 5 133 Remote operation ccoooocoooooooooooo00000000000000000 5 1 33 Remote operation for both systems eeeceeeeeeeeees 5 135 Remote PAUSE eecceccccccccc
197. DANT SYSTEM FUNCTIONS 5 1to5 142 5 1 Basic Concept of Redundant System coooooooooooooooooo00000000000000000000000000000000000000000000000000000009 D 1 5 1 1 Determination of System A System HB eoccoocoooocoooooooooooooooooooooo00000000000000000000000000000000000 H 3 5 1 2 Determination of Control System and Standby System eeeeeeesseecceecoeccoeccceccooccoocecoeseeee 5 5 5 1 3 Operation Mode 00oooooooooooooo0o00000000000000000000000000000000000000000000000000000000000000000000000000000 F 9 5 1 4 System Consistency Check C0000000 00000000000000000000000000000000000000000000000000000000000000000000000 5 15 5 1 5 Self Diagnostics Functione e esecccccccococcoooooo00000000000000000000000000000000000000000000000000000000000 5 25 5 1 6 Start Mode COOOL OO OOO OOOO OOO OOO OO OOOO OOOOH OOO OOOO OOO OOOO OOO OOOO OOO OOOO OOO OOOO OOOO OOO OOOO OO OOOOH OOOO OOOOOCCOD 5 28 5 2 FUNCTION LIST eecccccoccccoccoococococooooocococoocoocoococococoooooooocoooooooooooooooooooooooooooooooo0ooo0000 5 31 5 3 The System Switching FunCtION eeeeeeeeeeeeseeeeeeeececececececcceocoscoeocoososososososssososososososesesoe 5 32 5 3 1 System Switching Method seeeeeseseseeecececeeccocoosooosooosooossoosososososocococosososcceccceosessee 5 32 5 3 2 System Switching Execution Timinge eseeeeeeeseseeseeeseessecoosooooososososocosososososososososeoeoee 5 42 5 3 3 System Switching Execution Possibility eeeeeeeeeeesseseeesesosososososososososososc
198. DANT SYSTEM NETWORKS Mi aL 2G Kel ceries 6 4 Precautions for Accessing Redundant CPU from Other Networks A system using the MELSECNET 10 H or Ethernet can communicate with the redundant CPU by specifying the control system standby system System A or System B by z GX Developer or MC protocol However for accessing the redundant CPU from other networks networks of different network No there are the following restrictions on the CPU modules applicable to relay stations gt Table6 8 6 lt L fez Table6 8 CPU Modules Applicable to Relay Stations for Communication with Redundant CPU from Other Networks Z z Serial No of CPU module 06051 or earlier 06052 or later 25 eee Not Control standby System System Not Control Standby System System Bi Peu A B spectes system System A B QO00JCPU QOOCPU y Q01CPU Q02CPU 2 CPU module QO2HCPU x lt lt z model name QO6HCPU O O O O O O E Q12HCPU Q25HCPU Q12PHCPU zF Q25PHCPU Gas wo cr Zz Applicable x Inapplicable ASS We 2 OfS Oz Thoe W D D BO 56 Zr S ee TR ez wW 2 gt no z lt a z W a 9 X faa O z 2 W Zz PROGRAMMING CAUTIONS TROUBLESHOOTING 6 4 Precautions for Accessing Redundant CPU from Other Networks 6 49 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series Example Diagram 6 40 shows a system configuration example for making co
199. DUNDANT SYSTEM FUNCTIONS During Normal RUN and During Continuation Error During Stop In Backup Mode Control System Standby System During Stop Error During Normal RUN and During Continuation Error During Stop eLSEC KEY series During Stop Error Refresh between MELSECNET H PLC to PLC Network CPU Module gt Network Module Executes the function Transient Requested from Other Station in MELSECNET H PLC to PLC Network Executes the function Input from MELSECNET H Remote I O network Input Refresh from Network Module to Inputs it CPU Module Output to MELSECNET H Remote I O net Output Refresh From CPU Outputs it a OFF output Module to Network Module 1 SB SW Refresh from Network Module to CPU Module 2 SB SW Refresh from CPU Module to Network Module 2 5 72 Executes the function Executes the function 5 4 Operation Mode Change 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 Executes the function Inputs it Does not input it Does not output it Executes the function Executes the function Does not execute the function 5 REDUNDANT SYSTEM FUNCTIONS Mi aL 3G Kel ceries In Separate Mode Control System Standby System During Normal RUN During
200. Data tracking block specefication trigger we Zz og SM1583 9 a aa SES UW Resence absence of Continuous transition for Standby system error detection disable flag at ee SM323 i E SM1591 ane ae j entire blocks system switching 5 SM325 Output mode at block stop SM1592 Enable disable user system switching Copy contents of standard ROM during memor SM326 SFC device clear mode SM1598 a oe y 5 copy SM327 Output during end step execution SM1649 Standby system cancel error flag z 2 faye Disable prohibition of system switching durin Zr SM402 After RUN ON for 1 scan only SM1709 cuca Peewee 55 online program change u5 SM403 After RUN OFF for 1 scan only SM1710 Transfer tracking data during online program SM551 Reads module service interval change enable flag W E N gt N ZO ence ZO Be Llu W Pema 0 Z 2 no E S5 act O 0 zZ E Q fe ae ia a oc E 5 5 Tracking Function 5 83 5 5 3 Tracking Data D REDUNDANT SYSTEM FUNCTIONS 5 84 MELSEC A series d Special registers Table5 47 shows the automatically transferred special registers Special registers are only transferred in Backup Mode Table5 47 Automatically Transferred Special Registers Step transition watchdag timer setting value Enabled only when SFC program SD90 to SD99 i exists SD207 to SD209 LED display priority ranking SD210 to SD213 Clock data SD250 Loaded maximum I O SD315 Tim
201. Developer 5 6 2 Program Change While CPU is Running D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 5 7 Memory Copy From Control System To Standby System 1 Overview of Memory Copy From Control System To Standby System Function Memory copy form control system to standby system function transfers the parameters programs file register and other data from the control system CPU module to the standby system CPU module to make the standby system and control 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 OVERVIEW CONFIGURATION SYSTEM E A a a a Y Failed CPU module TRACKING CABLE Removing the CPU module 1 Standby Control system system 7 a EA moe e e g a E 5 3 lal B led J om o i A 3 Transfer i J Command nooo PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM oooooo oooooo Hot PLCupe PRH m4 Ol aL Ap Spare CPU module 2 Installing the CPU module W 12 gt no E Zz lt x ja Zz
202. Diagram 6 13 Overview of Remoto I O Station TROUBLESHOOTING 6 2 Redundant System Network Overview 6 15 6 2 2 MELSECNET H Remote I O network 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series 2 Redundant System Operation at System Switching When system switching occurs the new control system network module operates as the master station and takes over the control of remote I O stations Diagram 6 14 shows a redundant system operation when a stop error occurs in the control system CPU module Multiplexed Remote Master Multiplexed Remote Sub master Station station No 0 Station station No 1 Control system Standby system TEPE TERE Tracking cable MELSECNET H Remote I O network lgl sl fe Be Remote I O station Remote I O station station No 2 station No 3 Mutiplexed Remote Master gt St Mutiplexed Remote Sub master Master Station station No 0 op Station station No 1 station Control _ Standby Standby _ Control system System system System g
203. EC TA eries 4 Error clear processing is performed by END processing Therefore an error cannot be cleared unless the END instruction is executed with SM50 ON 2 Clearing the Standby System CPU Module Error by the Control System CPU Module Clearing the standby system CPU module error with the user program of the control system CPU module is performed using SM1649 and SD1649 Clearing the standby system CPU module error by GX Developer connected to the control system CPU module is also performed using SM1649 and SD1649 a Procedure Error clear is performed according to the following procedure 1 Remove the cause of the target error from the standby system 2 Store the corresponding error code into SD1649 in the control system CPU module 3 Turn SM1649 in the control system CPU module from OFF to ON 4 The target error is cleared from the standby system b Cautions 1 Error clear using SM1649 and SD1649 is enabled 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 Table8 2 Operation Modes Applicable to Clearing the Standby System Error using SM1649 and SD1649 CPU Module Performing Error Clear Control System CPU Module Standby System CPU Module Operation Mode Backup Mode O x Separate Mode x x Debug Mode Sta
204. EUROPE B V ITALY BG 1756 Sofia Phone 47 0 32 24 30 00 RU 620027 Ekaterinburg Italian Branch Phone 359 0 2 97 4405 8 Fax 47 0 32 8485 77 Phone 7 343 353 2745 Viale Colleoni 7 Fax 359 0 2 97 4406 1 MPL Technolo Fax 7 343 353 2461 gy Sp Z 0 0 POLAND ae Agrate pranda MI INEA CR d o 0 CROATIA UI Krakowska 50 F EE 16053312 Losinjska 4a PL 32 083 Balice aKF HR 10000 Zagreb Phone 48 0 12 630 47 00 MITSUBISHI ELECTRIC CORPORATION JAPAN Phone 385 0 1 36 940 01 02 03 Fax 48 0 12 630 47 01 MIDDLE EAST Office Iie Z a set Fax 385 0 1 36 940 03 Sirus Trading amp Services sri ROMANIA REPRESENTATIVES 812 1 chome Harami Chuo Ku AutoCont Control Systems s r o CZECH REPUBLIC Aleea Lacul Morii Nr 3 lan amp Gavish Ltd ISRAEL Tokyo 104 6212 i Phone 81 3 622 160 60 Jelinkova 59 3 RO 060841 Bucuresti Sector 6 Automation Service i a 62216075 CZ 721 00 Ostrava Svinov Phone 40 0 21 430 40 06 24 Shenkar St Kiryat Arie akt Phone 420 0 59 5691 150 Fax 40 0 21 430 40 02 1L 49001 Petah Tiqva MITSUBISHI ELECTRIC EUROPE B V UK Fax 420 0 59 5691 199 CRAFT Consulting amp Engineering d o o SERBIA Phone 972 0 3 922 18 24 oe e AutoCont Control Systems s r o CZECH REPUBLIC Bulevar Svetog Cara Konstantina 80 86 Fax 972 0 3 924 0761 Technologick 374 6 SER 18106 Nis Texel Electronics Ltd ISRAEL ea e aE Z 708 00 Ostrava Pustkovec Phone 381 0 18 292 24 4 5 523 962 Ha umanut P 0 B
205. EW a In the case of other than monitoring A communication error occurs when accessing to a module mounted on the extension base unit via the network using the function other than Monitor of GX Developer or PX Developer As for functions other than Monitor of GX Developer or PX Developer change the connection destination at Transfer setup and retry the communication For the command applicable in MC protocol via a module mounted on the extension base unit refer to Appendix 7 MELSOFT products connectable to 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 L gt GX Developer Version 8 Operating Manual CONFIGURATION SYSTEM L gt PX Developer Version 1 Operating Manual Programming Tool TRACKING CABLE 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 1 When Not Specified is Specified A communication error occurs when Not Specified has been specified as the connection target using GX Developer or PX Developer monitoring tool Change the connection target in the connection set up of GX Developer or PX Developer monitoring tool and restart communication REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A 2 When Control System
206. HOOTING 5 4 Operation Mode Change Function 5 57 D REDUNDANT SYSTEM FUNCTIONS 1 Operation Mode Change Procedure The operation mode change is performed in the control system CPU module by the redundant operation of GX Developer MELSEC TA eries a Changing from the Backup Mode to Separate Mode 1 Connect GX Developer to the control system CPU module 2 Select Online Redundant 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 STOP to remote RUN With this setting the CPU module starts running and executes Redundant operation Connection target information Connection interface Target PLC PLC status COMI lt gt PLC module RUN System type Remote operation C System switching C Memory copy Control system Station no Host PLC type Q25PRH Operation mode Backup mode Memory copy progress status Change operation mode BEREE hese x Select Separate mode 5 58 Run in backup mode BACKUP lt ON green Control system
207. Instruction The following shows the device and buffer memory used in the sample program of registering the user registration frame 1 Device of PLC CPU Table App 27 Device Used in the Program Device No Application Remarks X50 Register request command ON Register request M1 Flash ROM write request flag ON Flash ROM write request start M50 Register request set ON Registering 2 W O signal Table App 28 List of I O Signal I O signal GHZ side Signal name Description Flash ROM write completion ON Completed Flash ROM write request 3 Buffer memory Table App 29 List of Buffer Memory Buffer memory address Hexadecimal decimal ON Requesting Stored value CHE side Register read delete 0 No request 1 Registration request 2H 2 instructions 2 Read request 3 Deletion request wo Fame Noidtooton ea ame No Registration read delete O Normal compiation 444 4 Other than 0 Abnormal result storage i completion 0 No designation O Number of data bytes Other than 0 Number of registered designation data bytes registered maximum 80 bytes 6p to 2D4 6 to 45 User frame 0 No designation Other than 0 Registered data maximum 80 bytes Flash ROM write allow 2000 8192 a prohibit designation App 38 Appendix 6 Precautions for Using Serial Communication Module 0 Write prohibited 1 Write allowed MELSE LA s
208. MMING CAUTIONS MELSEC TA ories 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 Sooo coco ooo For the dedicated instructions for the intelligent function module refer to the manual for the intelligent function module to be used eeeeeeseeveeeeeneeeoeeeeseeeeeseeeeeeeeeeeseeneeeeeeeenee ee ee 8 7 1 Instructions Restricted in Use for Redundant System PROGRAMMING CAUTIONS MELSEC TAY series 7 2 Cautions on Fixed scan Clocks Programs i Z 1 Fixed scan Clocks SM409 to SM415 gt When system switching occurs fixed scan clock measurement is suspended until z system switching is complete When system switching is complete the new control system CPU module starts all fixed scan clocks from OFF rA fe Therefore the OFF time is extended T t as shown in Diagram 7 6 z The maximum value of the extension time when t t is T t Zo z Nz Control system R New standby system a 8 System switching activated Control system reagen 1 gene Fixed Cycle Clock SM409 to SM415 OFF E eee Bo ie f New standby system t i D S Non executed lt Sen Oo ram Z Standby system Begin system switching System Switching complete Fixed Cycle Clock ON SM409
209. Mi aL 20 fel ceries 4 Precautions Tracking cannot be performed in the following situations a If the tracking cable is disconnected or has a malfunction error message TRK DISCONNECT Make sure the tracking cable is connected or change the cable b If the following malfunctions occur on the standby system e Standby system power is off A stop error occurs on the standby system CPU module e The standby system CPU module is resetting Tracking can be performed if reset is cleared 5 76 5 5 Tracking Function 5 5 1 Tracking Function Overview D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 5 5 2 Tracking Execution Procedure The procedure for executing tracking in Diagram 5 47 fi z rA Perfom tracking E transfer according to defaults z Ze be sae no Use GX Developer to change tracking setting redundancy parameters See T page 5 5 3 a 3 Oo zZ xe Q x fe Use GX Developer to add tracking forwading triggers to the controlling program See page 5 5 4 ci w amp cr Zz aga Write to the CPU module parameters set Write to the CPU module parameters set 5 ES with GX Developer and programs with GX Developer and programs Qa ange Ol Perform a system restart Perform a system restart W no gt no E zZ lt Z a W a 2 Z O iS Z u Turn ON tracking forward trigger using the program W Ee
210. ND CH 8309 N rensdorf Jaakonkatu 2 Phone 41 0 44 838 48 11 FIN 01620 Vantaa Fax 41 0 44 838 48 12 Phone 358 0 207 463 500 Gs TURKEY Fax 358 0 207 463 501 Darulaceze Cad No 43 KAT 2 UTECO A B E E GREECE TR 34384 Okmeydani Istanbul 5 Mavrogenous Str Phone 90 0 212 320 1640 GR 18542 Piraeus Fax 90 0 212 320 1649 Phone 30 211 1206 900 F CSC Automation Ltd UKRAINE Fax 30 211 1206 999 15 M Raskova St FI 10 Office 1010 Meltrade Ltd HUNGARY UA 02002 Kiev Fert utca 14 Phone 380 0 44 494 33 55 HU 1107 Budapest Fax 380 0 44 494 33 66 Phone 36 0 1 431 9726 Fax 36 0 1 431 9727 Beijer Electronics SIA LATVIA Vestienas iela 2 LV 1035 Riga MITSUBISHI A ELECTRIC Phone 371 0 784 2280 Fax 371 0 784 2281 Mitsubishi Electric Europe B V FA European Business Group Gothaer Stra e 8 D 40880 Ratingen Germany FACTORY AUTOMATION Tel 49 0 2102 4860 Fax 49 0 2102 4861120 info mitsubishi automation com www mitsubishi automation com Specifications subject to change 01 2008
211. Normal RUN and During Resume During Stop During Stop Error and During Resume During Stop During Stop Error Error Error Executes refresh from network module to CPU Does not execute the module Does not execute the Executes the function function Does not execute refresh from CPU module to function network module Executes the function Executes the function Inputs it Inputs it Inputs it Inputs it Outputs it Turns OFF output Y Does not output it Does not output it Executes the function Executes the function Executes the function Does not execute the Executes the function Basen execute ne function function 5 4 Operation Mode Change Function 5 73 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol wW wn gt 2 Zz lt j zZ W ve 7 2 Q oO 2 5 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS Mi aL 26 fel ceries 5 5 Tracking Function 5 5 1 Tracking Function Overview 1 Tracking Function The tracking function maintains the data of the control system and standby systems consistent so that the redundant system can continue to operate with the standby system in case the control system goes down As the tracking data settings have been made by the default in the redundant CPU tracking can be done without changing the tracking settings
212. O ON green 2 9 Control system Standby system 5 Select Backup mode TAE Sg Bl E f 8 el P 30 8 RIFE Tracking cable W 2 gt no E Zz lt x a Zz Q W a 7 2 O QO 2 u GX Developer a n Diagram 5 34 Operation when Changing from Separate Mode to Backup Mode 2 The operation mode can be changed from the separate mode to backup mode by either of the Z following methods ZS Powering on system A and system B simultaneously mfa Setting the RESET 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 A the standby system CPU module resumes the Consistency Check Between 22 T oO Systems A and B S5 When returning to the backup mode make sure to make the settings so that Se the control system and standby system will be consistent in advance Refer to Section 5 1 4 for details on the Consistency Check Between Systems A and B 5 Q ae rt a O oc 5 4 Operation Mode Change Function 5 259 D REDUNDANT SYSTEM FUNCTIONS MELSEC TA ories 2 When returning to the backup mode from separate mode make sure to use the GX Developer that was used to change from the backup mode to separate mode However if the control system is powered off or if the control system CPU module is reset in the se
213. OEOOOE 5 59 Changing from the backup mode to separate MOE ecccccccccccccccccccccccccccccccccccccccccccsoscvceeee H 5 Confirming backup MOE ecocccccccccccccccccccccccccce 5 Confirming SM1511 and SM1512 to identify system A and system B eccccccccccccccccccccccccvcscsce 5A Confirming system A system B eeeeeeeeeeeeeeeee 4 10 5 4 Confirming that the power supply is ON eeeeeeeeeeee 4 9 Confirming the control system standby system coooooooooooooooooooooooooooooo0000000000000000 3 5 7 Confirming the Separate MOE seeeeeceecceceeseeecee 5 11 Connecting a tracking Cable eesseeeceeeeeeeceeceeee3 3 4 8 Connecting GX Developer eeecececccecccccccccccccccee 4 10 Connecting the Q6BAT battery connectors eeeseees 4 7 Consistency check eccccccccccccccccccccccccccccccccecee 5 45 Basic system configuration consistency CNECK ececccccccccccccccccccccccccvcvccccccccccccccccccce 5 20 File consistency CNECK cecccccccccccccccccccccccsccce 5 7 Memory card setting status consistency CNECK ececccccccccccccccccccccccccvcccccccccccccccccccese B 22 Operating status consistency check settings 5 19 Operation status consistency Check eeeeeeeeeeeee 5 18 Parameter valid drive settings consistency CNECK ececccccccccccccccccccccccccvcccvcccccccccccccccese 5 04 Consistency check execution conditionsesssssss 5 16 Consistency check points eccccccccccccccccccccccccccse D_ 5 CONTENTS eccccccccccccccccccccccccccccccccccccccccccse _ 1 CONTROL EXE ececccccccccccccc
214. OOOOH OOOO OOOO OO OOO OOOO OOO OOOO OOOOH OOO OOOO OOOOOCCD 5 93 5 5 8 Device Data Used By The New Control System CCOOOCOOOOOOOOOO000000000000000000000000000000000000000 5 98 5 6 Writing To The Both Systems Using GX Developerereecececccccccecccccccccccccccccccccccccccocccocooocccs 5 99 5 6 1 Writing to the CPU Module in STOP StatuSeccccccccccccccccccccccccccccccccccccccccccccccccccoccccccce 5 99 5 6 2 Program Change While CPU is Running cooooooooooooooooooooo0000000000000000000000000000000000000000 F 102 5 7 Memory Copy From Control System To Standby System cccocooooooooooooooo000000000000000000000000000 F 1 13 5 8 Online Module Change Hot SWAPPING eeceecceccccccccccccscccccccsecsecsoccoseccocsocccscesecsecsecoocvesel 125 5 9 Network Module Redundant Group Settings coooooooooooooooo0000000000000000000000000000000000000000000000 D 127 5 10 Redundant CPU Functions Restricted in Redundant SystemMee seeeeeeeseeesceceeecccceeocccoceoocoeeeo0 5 129 5 1 0 1 Enforced ON OFF of external I O 0oooooooooooooooooo0000000000000000000000000000000000000000000000000000 Hy 129 5 1 0 2 Remote Operation for Redundant System ccocoooocooooooooooooo00000000000000000000000000000000000000 133 5 11 Access to Module Mounted on Extension Base Uniteeesecccccococooooooooooooo0000000000000000000000000005 141 CHAPTER6 REDUNDANT SYSTEM NETWORKS 6 1 to 6 52 6 1 Communication with GX Developer and PX Developer ccoocooocoooooo00000000000000000000000000000
215. Other Than Control Standby Control Standby SO 46 System switching will not be executed Zr Watchdog Timer Errors System System System System ag WD Control Standb Control Standb ee Watchdog Timer Error 4 System switching will not be executed System System System System Cannot change from Separate Mode to Control Standby Control Standby 9 p Hardware Failure Backup Mode due to a control system System System System System f o hardware failure EA Aoma Cannot change from Separate Mode to Zo System Control Standby Control Standby g p az Switchin Power OFF System System Svafeni System Backup Mode due to control system 58 g y 4 4 7 power OFF D u Cannot change from Separate Mode to Control Standby Control Standby E p Reseting Backup Mode due to control system System System System System reset status System Switchin 3 Control Standby Control Standby R g Request by Network System switching will not be executed Zz System System System System 2 w Module lt 2 ac System Switchin Control Standb Standb Control OF S 3 7 y System switching will not be executed 22 Manual Using GX Developer System System System System 2o System System Switching b 2 7 ie ks Control Standby Standby Control ee Switching System Switching System switching will not be executed System System System System Instruction g E Q fe ae N W a 2 5 3 The System Switching Function 5 49 5 3 3 System Switching Execution Possibility D REDUND
216. PLOADP Program Load from Memory Card RESY Pulse Output PUNLOADP Program Unload from Memory Card PWM Pulse Width Modulation PSWAP Load Unload MTR Matrix Input PR Print ASCII code S TO Write To Host Station CPU Shared Memory PRC Print Comments S P SFCF Request of Motion SFC Program Startup KEY Numerical Key Input S P SVST Request of Servo Program Startup Axis Speed Change during Positioning and JOG UDCNT1 1 phase Input Up Down Counter S P CHGV p g 9 g operation Torque Control Value Change during Operation and UDCNT2 2 phase Input Up Down Counter S P CHGT oe 9 g Sp Suspension in Real Mode Current value Change of Halted Axis Synchronized TTMR Teaching Timer s P cHea ak z Encoder Cam axis Write Host CPU Device Data into Other CPU STMR Special Timer S P DDWR devices ROTC Rotary Table Near Path Rotation Control S P DDRD Read Other CPU Device Data into Host CPU RAMP Ramp Signal Eee S P GINT Request of Other CPU Interrupt Program Startup SPD Pulse Density Measurement Table App 8 Instructions Restricted for PRHCPU Instruction Symbol COM Selection Refresh 77 For restrictions on COM and ZCOM refer to Section 7 1 7 ZCOM Refresh of Specified Module Instruction Name Remark App 10 Appendix 3 Comparison of QNPHCPU and QnPRHCPU APPENDICES MELSEC LA series Appendix 4 Sample Programs when Using CC Link This section explains sample programs that allow the CC Link control to be continued whe
217. PU complete GX Developer Diagram 5 83 shows the operation performed when memory copy is executed 3 Memory Copy From Control System to Standby System Using Special Relays and Special Registers The following provides the procedure for executing memory copy function using the special relays and special registers and the relevant operations a Steps 1 Connect the control system and the standby system with the tracking cable and turn the standby system power ON Control system CPU module Standby system CPU module a ON red Q12PRHCPU Q12PRHCPU MODE BACKUP MODE BACKUP m RUN E CONTROL RUN Se CONTROL ERR E SYSTEMA ERR a SYSTEMA USER J SYSTEMB L ON red USER SYSTEMB BAT LJ BAT BOOT BOOT ON red Flashing red Diagram 5 84 LED Indications when Tracking Cable Is Connect 1 Ifthe 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 Make sure SM1596 and SM1597 are turned OFF If SM1596 or SM1597 is ON turn it OFF 5 7 Memory Copy From Control System To Standby System 5 119 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol
218. PU module to neutral position within three seconds after making the same settings for the other CPU module POINT When switching power on again switch power on more than 5 seconds after switching power off Failure to do so may disable a normal start of the redundant system because an inrush current of higher than the specified value may flow or the tracking communication circuit in the CPU module may not be initialized 4 9 Error Check Confirm that no error has occurred in the CPU module by checking the ERR LED Table4 2 Checking the ERR LED to Check for Errors CPU Module LED LED common to System A and System B am TepName MODE BACKUP ERR ON Flashing RUN CONTROL ERR SYSTEM A USER ISYSTEM B BAT BOOT If any error has occurred in the CPU module check the details by using the PLC diagnostics of GX Developer Refer to the following manual for details on CPU module LEDs lt gt QCPU User s Manual Hardware Design Maintenance and Inspection 4 12 4 8 Restarting System A and System B PROCEDURE FOR STARTING UP A REDUNDANT SAE MELSEC Kel ceries 4 10 Confirming the Control System Standby System Identify the control system standby system by checking the CONTROL LEDs Table4 3 Checking the CONTROL LED to Identify Control System and Standb
219. Points and Current A CO to C1023 CO to C1023 i Value Data Register l DO to D12287 DO to D12287 Link Register WO to W1FFF WO to W1FFF Link Special Register SWO to SW7EF g p b Index Register Z0 to Z15 Z0 to Z15 m re Special Relay 3 5 a z 6 Special Register 4 5 8 z a File Register ZRO to ZR1042431 EE Ol Indicates data that is set to be not tracked by default 1 The number of device points to be used can be changed in the PLC parameter device settings using GX Developer If the number of points to be used is changed the number after change will be the default tracking range or the tracking range set by user 2 The number of retentive timer points is 0 by default When setting the number of retentive timer points to be used in the PLC parameter device settings of GX Developer the set number will be the default tracking range or the tracking range set by user wW 2 gt no E zZ lt q z a W a 7 2 O oO Zz u 3 For the special relays the data in the range shown in Table5 46 will be automatically tracked a 4 For the special registers the data in the range shown in Table5 47 will be automatically tracked 5 Special relays and special registers used in the redundant system are transferred automatically Em The tracking transfer range cannot be set by the user Sk 6 Do not perform the tracking transfer to the link special relay SB and link speci
220. Q W a 7 2 O QO 2 u GX Developer 1 to 4 shows the steps up to transferring a Executing memory copy Memory copy can be executed using either of the followings e GX Developer e Special relays and special registers REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 7 Memory Copy From Control System To Standby System 5 113 D REDUNDANT SYSTEM FUNCTIONS Mi aL 20 Cel ceries b Special Relays and Special Registers for Memory Copy Table5 58 shows the special relays and special registers for the memory copy function Table5 58 Special Relays and Special Registers for Memory Copy Aen Set by User Type Number Description Remarks or System SM1595 Turn on this relay to start memory copy after storing User Specific to control 3D1H into SD1595 system CPU module Applicable to both This relay turns on during memory copy control system and smis96 Sea 3 y Sopy System 7 This relay turns off after memory copy 1 standby system CPU modules Special This relay turns on after memory copy 1 f a Y OPY Applicable to both Relays Turn off this relay when starting memory copy System control system and SM1597 In the case of memory copy by GX Developer GX i User standby system CPU Developer will turn off this relay before starting memory modules copy Turn on this relay when not copying memory from p Specific to control SM1598 standard ROM User f system
221. R REDUNDANT SYSTEMS n w Q a z i a a lt WARRANTY Please confirm the following product warranty details before using this product 1 Gratis Warranty Term and Gratis Warranty Range If any faults or defects hereinafter Failure found to be the responsibility of Mitsubishi occurs during use of the product within the gratis warranty term the product shall be repaired at no cost via the sales representative or Mitsubishi Service Company However if repairs are required onsite at domestic or overseas location expenses to send an engineer will be solely at the customer s discretion Mitsubishi shall not be held responsible for any re commissioning maintenance or testing on site that involves replacement of the failed module Gratis Warranty Term The gratis warranty term of the product shall be for one year after the date of purchase or delivery to a designated place Note that after manufacture and shipment from Mitsubishi the maximum distribution period shall be six 6 months and the longest gratis warranty term after manufacturing shall be eighteen 18 months The gratis warranty term of repair parts shall not exceed the gratis warranty term before repairs Gratis Warranty Range 1 The range shall be limited to normal use within the usage state usage methods and usage environment etc which follow the conditions and precautions etc given in the instruction manual user s manual and caution labels on the produc
222. RAMMING CAUTIONS TROUBLESHOOTING 5 8 Online Module Change Hot Swapping 5 125 D REDUNDANT SYSTEM FUNCTIONS 5 126 3 4 MELSE TA ories Redundant Power Supply Module When a pair of redundant power supply modules is used in each system of the redundant system one redundant power supply module can be replaced at a time after powering off the module As another redundant power supply module 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 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 control system or standby system main base unit the module can be replaced without stopping system control Note that a module mounted to the main base unit cannot be replaced online when the extension base unit is connected Refer to the following manual for details lt QCPU User s Manual Hardware Design Maintenance and Inspection 5 8 Online Module Change Hot Swapping D REDUNDANT SYSTEM FUNCTIONS 5 9 Network Module Redundant Group Settings Control system OPS 1 Network Module Redundant Group Settings When a pair of Ethernet modules is used in each syste
223. RATION 2 2 Peripheral Device Configuration E Redundant CPU Memory Card RS 232 Cable E Personal Computer GX Developer PX Developer GX Simulator i F USB Cable MELSEC TA eries Pi LL gt Memory Card PC Card i Adapter Diagram 2 9 Peripheral Device Configuration 1 Do not format ATA cards for using other than GX Developer L3 QCPU User s Manual Hardware Design Maintenance and Inspection 2 Refer to the following manual for details on writing to memory card and USB cable lt gt GX Developer Operating Manual 3 Refer to Section 2 3 for versions of GX Developer PX Developer and GX Simulator applicable to redundant CPU 2 10 2 2 Peripheral Device Configuration 2 SYSTEM CONFIGURATION Mi eL ECLA ceries 2 3 Applicable Devices and Software This chapter describes modules and software packages used to configure a redundant system OVERVIEW N 1 Modules applicable to redundant system and the confirmation measures Modules that can be mounted on the same main base unit as a redundant CPU and the confirmation are indicated in Table2 1 2 Q z 5 o iE 2 Oo oO SYSTEM Table2 1 Modules that can be mounted on the same Main Base Unit as Redundant CPU and the Confirmation Measures Module Name Model Serial Number
224. S MELSEC LA series Table App 6 Comparison of QNPHCPU and QnPRHCPU Continued Item System expansion using extension base units QnPRHCPU Restrictions for Mounting Modules on Remote I O Stations FROM TO instructions and intelligent function module devices U G are inapplicable Intelligent function modules use REMFR REMTO instructions for buffer memory access Set the remote I O station intelligent function module using GX Configurator 2 e The following modules cannot be mounted to remote I O station e MELSECNET H network module interrupt module Web server module e Ethernet interface modules cannot make a communication using dedicated instructions interrupt pointers e mail functions or fixed buffer and do not support FTP server functions or web server functions e Intelligent function modules other than above do not support dedicated instructions or interrupt QnPHCPU Applicable Extension base units maximum 7 levels points Multi CPU System N A Applicable Single CPU System Applicable Debug mode only Applicable Bus Connection N A Applicable CPU Direct Applicable Communication with the CPU module Apolicable Connection connected to the GOT only Pp Computer Link Connection N A Applicable A Eth t Connection eee Applicable Applicable Type Connection CC Link i Connection Applicable Applicable MELSECNET H Remote A Station Applicable N A for extension base
225. SYSTEM Checking the system where 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 TRACKING CABLE l Turning OFF power supply of standby system l PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM Replacement of an extension cable of the standby system Disconnect an extension cable from the main base unit Connect the extension cable to be replaced to the main base unit W D D by Turning ON power supply of standby system a2 2 S Ei Check that RUN STOP switch of the standby system CPU module is set to RUN STOP T position Check that RESET L CLR switch of the control system CPU module is set to center position reset cancel Turn ON power supply of the standby system N a l ag Checking POWER LED of the power supply module 5s W W Check that POWER LED of the power supply module is turned ON green and power supply is BE supplied normally Start standby system 2 o Diagram 8 33 Replacement Procedures of Extension Cable Se OS act O 00 o Zz Q O T o wW a O iv E 8 3 Replacing Module in Redundant System 8 47 8 3 10 Replacement Procedures of Extension Cable 8 TROUBLESHOOTING M BLS AG Qa Memo 8 48 8 3 Replacing Module in
226. Special Registers For System Switching Continued Setting at Time of System Switching Device No Description z 2 Qo Uo c5 eo a o 2 3 3 Oo lt a2 oO 32 i og c5 z2 gz Ko OVERVIEW Stores system switching condition that occurred on that system Stores system switching condition even when system cannot switch due to system switching disenabling condition Initializes at 0 at power ON reset gt clear sp1588 System Switching 0 Initial value system switching has not yet occurred Condition 1 Hardware failure watchdog timer error 2 Stop error except watchdog time error 3 System switching request from network module 16 System switching instruction 17 System switching request from GX Developer CONFIGURATION SYSTEM When system switching occurs due to a system switching condition the system switching disenabling condition when 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 System Switching 3 Hardware failure power OFF resetting or watchdog timer error occurring SD1589 Disenabling on control system Condition 4 Preparing for tracking communication 5 Communication timeout 6 Stop error on standby system exc
227. Status Configuration Settings Drive Settings Status Status Both systems powered on Backup Mode O O O O simultaneously Both systems Unreset Backup Mode O O O O O simultaneously RUN o O STOP RIN PAUSE g O E STOP RUN O O RUN STOP STOP O 7 PAUSE PAUSE Backup Mode STOP RUN O END processing RUN O O STOP RUN STOP PAUSE O E Power ON TUN O O O O 3 STOP Unreset _ PAUSE O O O E RIUN RUN O O O O Soe STOP RUN Separate Mode paren STOP to Backup Mode PAUSE O O O Unreset RUN RUN O O O O Tracking cable Backup Mode Bae RUN reconnected STOP O O O PAUSE PAUSE 5 416 5 1 Basic Concept of Redundant System 1 The consistency check is executed only in the following cases O Consistency Check Target Out of Consistency Check Target After online program change is completed the consistency check is executed only for the program files At system switching The consistency check is executed under the above conditions only 2 The consistency check is not executed under any other conditions not listed in the table 3 Unreset indicates that the RESET L CLR switch is set to the neutral position Remark Sooo ooo occ ore The consistency check will not be executed during the following e Memory copy from control system to standby system eeseeeeeceovoeaeeceaseaceeesceoseecoeeeeceeeeeeeeeceaeseeeeae
228. StraBe 8 AT 2500 Baden LT 02300 Vilnius KAZ 470046 Karaganda D 40880 Ratingen Phone 43 0 2252 85 55 20 Phone 370 0 5 232 3101 Phone 7 3212 50 1150 Phone 49 0 2102 486 0 Fax 43 0 2252 488 60 Fax 370 0 5 232 2980 Fax 7 3212 50 1150 Fax 49 0 2102 486 1120 TEHNIKON BELARUS _INTEHSIS srl MOLDOVA ELEKTROSTILY RUSSIA MITSUBISHI ELECTRIC EUROPE B V FRANCE Oktyabrskaya 16 5 Off 703 711 bld Traian 23 1 Rubzowskaja nab 4 3 No 8 French Branch BY 220030 Minsk MD 2060 Kishinev RU 105082 Moscow 25 Boulevard des Bouvets Phone 375 0 17 210 46 26 Phone 373 0 22 66 4242 Phone 7 495 545 3419 F 92741 Nanterre Cedex Fax 375 0 17 21046 26 Fax 373 0 22 66 4280 Fax 7 495 545 3419 e oy F 2 68 Koning amp Hartman B V BELGIUM Koning amp Hartman B V NETHERLANDS ICOS RUSSIA ax 33 0 Industrial Solutions Haarlerbergweg 21 23 Industrial Computer Systems ZAO MITSUBISHI ELECTRIC EUROPE B V IRELAND Woluwelaan 31 NL 1101 CH Amsterdam Ryazanskij Prospekt 8A Office 100 Irish Branch BE 1800 Vilvoorde Phone 31 0 20 587 76 00 RU 109428 Moscow Westgate Business Park Ballymount Phone 32 0 2 257 02 40 Fax 31 0 20 587 76 05 Phone 7 495 232 0207 IRL Dublin 24 Fax 32 0 2 257 0249 Beijer Electronics AS Norway Fax 7495 232 0327 ie o A AKHNATON BULGARIA Postboks 487 NPP URALELEKTRA RUSSIA ax 353 0 4 Andrej Ljapchev Blvd Pb 21 NO 3002 Drammen Sverdlova 11A MITSUBISHI ELECTRIC
229. System A Contro System B Standby System 5 2 ee aj m g eve IPER 35 Tr 6 W 12 gt no z lt x Q Zz Q W a n 4 iva O z 2 W Zz Normal transmission G Z System A Control System System B Standby System 22 TO b g oe 2 3 Oe KS gp 8 E al g 22 iie a B ot Communication 4 m fel O not possible gt a Bl ALE g H oHe Tracking cable J 0 zZ E Diagram 6 22 Operation at Communication Error Detection 8 5 W a oc E 6 2 Redundant System Network Overview 6 25 6 2 3 Ethernet 6 REDUNDANT SYSTEM NETWORKS 3 MELSEC TE ories b Communication with the Control System Standby System by MC Protocol or Data Link Instructions Even when system switching occurs in a redundant system communication can be continued if the communication path is normal When the communication cannot be continued the external device develops a communication error In this case review the communication path and restart the communication c Communication other than above When system switching occurs in a redundant system the external device develops a communication error oc
230. System Switching Execution Possibility D REDUNDANT SYSTEM FUNCTIONS Operating Status Normal MELSEC fA series Table5 27 Operating Status and Details Description The CPU module is in the RUN STOP or PAUSE status where no error such as a continuation error or stop error has occurred Continuation The CPU module is in the RUN STOP and PAUSE status where a continuation error has occurred Error 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 MELSECNET H network module Ethernet interface module PROFIBUS DP master module Preparing for The communication is not made between the control system and standby system via tracking cable Tracking System Switching The system switching has not been completed as a data error occurred due to noise etc in the Request communication between the control system and standby system during system switching processing Timeout Executing eat f Seen System switching cannot be executed since the control system or standby system is executing system es switching due to the previous system switching condition Switching 5 44 POINT 1 Make sure to set CPU Operation Mode to STOP default on the details settings of the PLC
231. System Switching Request 4 When Group Settings are made on a Network Module Inapplicable to Redundant System If group settings are made on a network module inapplicable to the redundant system the PARAMETER ERROR error code 3000 stop error will occur In this case check the network parameter group settings 5 128 5 9 Network Module Redundant Group Settings 5 REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 5 10 Redundant CPU Functions Restricted in Redundant System This section explains the following Redundant CPU functions that are restricted in a redundant system e Enforced ON OFF of external I O e Remote operation Refer to the following manual for details of each function C gt QCPU User s Manual Function Explanation Program Fundamentals OVERVIEW 5 10 1 Enforced ON OFF of external I O CONFIGURATION SYSTEM The 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 For details of the enforced ON OFF of external I O refer to the QCPU User s Manual Function Explanation Program Fundamentals TRACKING CABLE 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 of the forced I O ON OFF status is made to the s
232. Tracking Block No 8 Tracking Trigger z9 SM1528 Tracking Block No 9 Tracking Trigger 96 SM1529 Tracking Block No 10 Tracking Trigger OFF Disable ae SM1530 Tracking Block No 11 Tracking Trigger Tracking OFF User BE SM1531 Tracking Block No 12 Tracking Trigger ON Enable SM1532 Tracking Block No 13 Tracking Trigger Tracking SM1533 Tracking Block No 14 Tracking Trigger SM1534 Tracking Block No 15 Tracking Trigger Z SM1535 Tracking Block No 16 Tracking Trigger Zg SM1536 Tracking Block No 17 Tracking Trigger JE SM1537 Tracking Block No 18 Tracking Trigger ea SM1538 Tracking Block No 19 Tracking Trigger SM1539 Tracking Block No 20 Tracking Trigger SM1540 Tracking Block No 21 Tracking Trigger S 8 ui a 8 5 5 Tracking Function 5 89 z 5 5 5 Tracking Block And Tracking Trigger Number SM1541 REDUNDANT SYSTEM FUNCTIONS Tracking Block No Table5 49 Tracking Triggers Continued 22 Tracking Trigger SM1542 Tracking Block No 23 Tracking Trigger SM1543 Tracking Block No 24 Tracking Trigger SM1544 Tracking Block No 25 Tracking Trigger SM1545 Tracking Block No 26 Tracking Trigger SM1546 Tracking Block No 27 Tracking Trigger SM1547 Tracking Block No 28 Tracking Trigger SM1548 Tracking Block No 29 Tracking Trigger SM1549 Tracking Block No 30 Tracking Trigger SM1550 Tracking Block No 31 Tracking Trig
233. U module from GX Developer in the other route the standby system CPU module is not reset if remote operation is performed for the control system CPU module 1 When performing remote reset for 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 Control system Standby system Tracking cable GX Developer Jl Control RUN gt STOP Standby system Remote operation RUN gt STOP Connection target information Connection interface COM1 lt gt PLC module Target PLC Station no Host PLC type Q25PRH PLC status RUN System type Standby system Operation mode Backup mode Tracking cable Operation Specify execution destination pic STOP Currently specified station Alllstations Specific group i Both systems A amp B C Extract memory card 5 Remote operation Control STOPReset STOP standby STOP Connection target information system Connection interface COM1 lt gt PLC module Target PLC f Stationno Host PLC type Q25PRH bae PLC status STOP
234. When disposing of this product treat it as industrial waste Transportation Precautions CAUTION When transporting lithium batteries make sure to treat them based on the transport regulations Refer to QCPU User s Manual Hardware Design Maintenance and Inspection REVISIONS Print Date Jun 2004 Jun 2005 Aug 2005 Mar 2006 Jun 2006 Jun 2006 Dec 2006 Apr 2007 Manual Number SH NA 080486ENG A SH NA 080486ENG B SH NA 080486ENG C SH NA 080486ENG D SH NA 080486ENG E SH NA 080486ENG F SH NA 080486ENG G SH NA 080486ENG H The manual number is given on the bottom left of the back cover Revision First edition Partial correction GENERIC TERMS AND ABBREVIATIONS Chapter 1 Section 2 3 6 2 2 8 1 1 8 3 3 9 1 9 2 Partial correction GENERIC TERMS AND ABBREVIATIONS Section 2 1 2 3 Chapter 4 Section 5 1 3 5 1 4 5 3 1 5 4 5 5 1 5 5 3 5 5 6 5 5 7 5 6 2 5 7 5 9 6 2 1 7 1 8 3 3 9 2 Appendix 1 Appendix 4 Partial correction GENERIC TERMS AND ABBREVIATIONS Section 2 1 2 3 4 2 5 3 5 6 2 2 Appendix 4 3 Appendix 4 5 Addition function QJ71PB92V Addition Section 6 2 6 Partial correction ABOUT MANUALS Section 1 2 2 1 2 3 5 3 1 5 3 4 6 2 7 1 9 2 Addition function SAFETY PRECAUTIONS Appendix 4 3 Section 2 3 2 4 Appendix 4 5 Addition function SAFETY PRE
235. X Developer 5 105 5 6 2 Program Change While CPU is Running D REDUNDANT SYSTEM FUNCTIONS 5 106 MELSE TA ories However even if the program of the new control system CPU module has not been changed due to the system switching timing the data calculated in the previous control system after system switching may be tracked System A CPU module System B CPU module Control system Standby system Device Program Program DEVIGE data 9 9 data Data before Data before changin changing e ging Perform write during RUN Data after change Z Perform write during RUN 7 Data after change If a system switching occurs in this zone the System B CPU module will perfom control based on device data calculated by the program after modification Diagram 5 66 Program and Device Data due to System Switching Timing 5 6 Writing To The Both Systems Using GX Developer 5 6 2 Program Change While CPU is Running 5 REDUNDANT SYSTEM FUNCTIONS MELSE LA series 4 System Switching During Online Program Change Table5 54 shows the operation when the reason for system switching occurs during z online program change a Table5 54 System swiching During RUN Write Redundancy Compliance Execution System Switching Z System swiching Condition Execution During RUN 2 x H fez Write z z Stop error O DZ Automatic System swiching request by n
236. YSTEM b A communication error occurs between the CPU modules during manual system switching or a system switching due to a stop error c When any of the followings happens to the standby system at the same time as a tracking cable failure during manual system switching or system switching due to a stop error e The standby system is powered off or its CPU module is reset e A stop error occurs in the standby CPU module e Control system and standby system CPU module operating statuses are different e A standby system network module failure TRACKING CABLE Operations when the system switching fails due to one of a to c shown in the Table5 40 below REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Table5 40 System A and B CPU Module Operations When the System Switching Fails Function System A and System B CPU Module Operation 3 CPU Module Operating Status Standby System Operation 2 Red i 3 cs BACKUP ed light ON in Back p Mode Ea LED Indication Amber light ON in Separate Mode 36 CONTROL Light OFF 55 SM1516 TE Special Relay ON Standby system Operation System Status System Switching Request from Network Module System Switching POES Cannot execute system switching instruction cannot be executed due to System Switching Instruction Request standby system operation System Switching Request Cannot execute system switching from GX Developer etc Returns error code 4240H on startup
237. YSTEM NETWORKS Mi ELSEG A series Example Diagram 6 9 shows the redundant system operation when the control system network module detects a communication error on the assumption that the z control system network module is the control station of station No 1 and the a gt standby system network module is the normal station of station No 2 Normal station Normal station Station No 3 Station No 4 ot mm N eI gl 2 O z 5 ae 26 no MELSECNET H PLC to PLC network gt a Control station Normal station w i i m Control system Station No 1 _ Standby system Station No 2 a a O a 2 al aio o E BIE D 83 Al H Z i kad a System switching reques hl G lal z E g g oc a 0 E g l 2 g BE Tracking cable Operation when a communication error occurs ci in the MELSECNET H PLC to PLC network oe 2 w amp 2 EE aga SES Normal station Normal station 8 ra Station No 3 Station No 4 Tbe E
238. a MITSUBISHI ELECTRIC MELSEC System Q Programmable Logic Controllers Users s Manual Redundant System QnPRHCPU Q12PRHCPU Q25PRHCPU Art no 164264 10 04 2007 Sn coke aa MITSUBISHI ELECTRIC INDUSTRIAL AUTOMATION Version H ersion SAFETY PRECAUTIONS Always read these instructions before using this equipment Before using this product please read this manual and the relevant manuals introduced in this manual carefully and pay full attention to safety to handle the product correctly In this manual the safety instructions are ranked as DANGER and CAUTION D DANGER Indicates that incorrect handling may cause hazardous conditions resulting in death or severe injury A Indicates that incorrect handling may cause hazardous conditions CAUTION resulting in medium or slight personal injury or physical damage Note that the NCAUTION level may lead to a serious consequence according to the circumstances Always follow the instructions of both levels because they are important to personal safety Please save this manual to make it accessible when required and always forward it to the end user Design Precautions Install a safety circuit external to the PLC that keeps the entire system safe even when there are problems with the external power supply or the PLC module Otherwise trouble could result from erroneous output or erroneous operation 1 Outside the PLC construct mechanical da
239. a a during online program change 5 Internal device Table5 44 Special relay Table5 46 Special register Table5 47 z SFC data Section 5 5 3 2 g PID control instruction data Section 5 5 3 2 o Make sure to set SM1710 to on or off whether or not to execute tracking before 26 executing online program change If the special relay is turned on during online program change tracking will not be executed z S E ai woe aga OES Ol wW no gt 2 E zZ lt z Q W a 7 2 Q oO 2 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 6 Writing To The Both Systems Using GX Developer 5 103 5 6 2 Program Change While CPU is Running D REDUNDANT SYSTEM FUNCTIONS 5 104 a When SM1710 is OFF Default When SM1710 is off tracking will be suspended until online program change is complete MELS SCTE cries If a system switching occurs during online program change the new control system CPU module may output old data For example if output Y is turned on in the control system during online program change the output Y on information will not be tracked to the standby system CPU module since tracking has not been performed If system switching occurs under these conditions output will turn on and off at the time of the system switching Circuit before program change in ladder mode during RUN MO MO Circuit is added to
240. aced Pa 7 cr Zz 204 Replace the standby system CPU module after powering off the standby system R 5 The standby system can be powered off even while the redundant system is running 228 Control system em fz fea a El i 3 8 on g gi Zz 3 3 oF ag Tracking cable WD T i Replace after turning OFF F GX Developer the standby system power Diagram 8 16 System where Standby System CPU Module is Replaced Z W W 2 Replacement Procedure aS The procedure for replacing the CPU module is shown in Diagram 8 17 Z Confirming the System of the Replacement Target CPU Module 6 Confirm that system of the target CPU module is the standby system the CONTROL LED is 95 O off When replacing the control system CPU module switch its system to the standby system using GX Developer Refer to Section 8 3 1 for system switching using GX Developer l Power OFF the Standby System o Zz Q O T o wW a O iva E 8 3 Replacing Module in Redundant System 8 31 8 3 1 CPU Module Replacement 8 TROUBLESHOOTING 8 32 Disconnecting the Tracking Cable MELSEC TA ories Disconnect the tracking cable from the standby system CPU module Refer to Section 3 3 for disconnecting the tracking cable l Replacing the Standby System CPU Module 1 2 Connecting the Tracking Cable Remove the standby system CPU module from the main base unit Mount an alternative CPU m
241. acking data range cannot be changed by the user Refer to Section 5 5 3 for details on the tracking data settings Changing Tracking Data Settings The tracking data range settings can be changed in the following cases e To shorten the tracking time To add to the tracking data file register etc To change the tracking timing in a program e To track signal flow memory Change the tracking data setting at the tracking settings in the redundant parameter settings of GX Developer Refer to Section 5 5 4 for details on changing the tracking data settings Remark Seo ooo ooo oer 1 When changing the tracking data settings at the tracking settings in the redundant parameter settings the data can be divided into blocks tracking block Each block can be set to be tracked or not for each scan with the special relay for data tracking execution Data tracking block specification trigger SM1520 to SM1583 Refer to Section 5 5 5 for details on tracking blocks and tracking triggers eeeeseeeaeeveceeoeaeeeaoeceeeeaeeceaoeeseeceeec eee eco eee eeeeeeeae eee eee 6 5 5 Tracking Function 5 75 5 5 1 Tracking Function Overview OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol W i gt no E zZ lt q Z Q W a 2 Zz O S Z u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS
242. ae aa me 1 0ma 2000rra M Carry out fuse blown check h iad Ome 200m M Carry out fuse blown check 5 monitoring time ms 10ms 2000ms V Cary out 1 0 module comparison monitoring time ms 10ms 2000ms V Carry out 1 0 module comparison a o Low speed ms 10ms 2000ms Constant scanning Low speed sms 10ms 2000ms Constant scanning 5 5 execution execution O monitoring time ms 0 5ms 2000ms monitoring time ms 0 5ms 2000ms no Operating mode when there is an error Operating mode when there is an error Computation error Stop zj Low speed program execution time Computation error Low speed program execution time Expanded command error Stop X ms 1ms 2000ms Expanded command error ms 1ms 2000ms Fuse blown Stop fhd Fuse blown Stop Fi 140 module comparison error Stop Breakdown history 140 module comparison error Stop PREG history W Intelligent module program co el Record in PLC RAM Intelligent module program m execution error op Record in the following history file execution error O Memory card access error Stop Zi Corresponding Memory card access error Corresponding a Z Memory card operation eror Stop beets _ _ __ Memory card operation error Py a E External power supply OFF Stop id i External power supply OFF cone i History No Item 16 100 History No fi Item 16 100 Default Check End Cancel Default Check End Cancel 2 lt 2 Diagram 6 19 In the case of Redundant
243. al No is 09011 or earlier gt gt 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 64 Slots Main base unit Extension base unit 7 stages Maximum Number of Modules Mounted on Main Extension Base Unit modules per station lt lt First 5 digits of serial No is 09012 or later gt gt Up to 63 modules Main base unit extension base unit 7 stages lt lt First 5 digits of serial No is 09011 or earlier gt gt N A Modules for the expanded system are mounted System to MELSECNET H remote I O station ceniouaiog lt lt First 5 digits of serial No is 09012 or later gt gt Applicable Extension base unit Up to 7 stages The following modules cannot be mounted Interrupt module MELSECNET H network module Ethernet interface module function version B or earlier e High speed logging is not applicable when the Web server module is used e High speed collection is not applicable when the MES interface module is used e Interrupt pointer and dedicated instruction are not applicable when the intelligent function module is used System expansion using extension base units Applicable Extension base units maximum 7 levels 1 Q4ARCPU repeat mode results in program priority mode on QnPRHCPU App 8 Appendix 3 Comparison of QnPHCPU and QnPRHCPU System Configuration APPENDICE
244. al completion 25714 599 267 615 Data transmission result 1 or more Abnormal completion error code 400 4 1024 800 4 2048 Transmission data count 0 No designation designation 1 or more Number of send data 401p to 5FFy 801 to 9FFy Transmission data Data to be sent to an external 1025 to 1535 2049 to 2559 designation device App 44 Appendix 6 Precautions for Using Serial Communication Module APPENDICES MELSEC TAY series The program example of sending data by the nonprocedural protocol communication is shown in Diagram App 30 For the I O signal is X Y80 to X Y9F PROCESSING TIME FOR REDUNDANT SYSTEMS X50 X9E X9F X80 X81 Y80 o 4 K 44 d 4 46 MOV abcdefg Di fmovP HOAOD D15 O Sets send data and number of send data vow K5 Dio TOP H8 H400 D10 K6 q Writes the number of send data and send data to buffer memory J APPENDICES SET yso 1 Turns ON send request signal Y80 5 after writing data X80 2 5 23 RST Y80 Turns OFF send request signal x lt XB Reads send error code 3 25 FROMP H8 H257 D20 Ki J Take corrective action to the error 2 according to error code stored in D20 RST Y80 Turns OFF send request signal X60 32 YsE Turns LED OFF and clears error code Diagram App 30 Program Example Appendix 6 Precautions for Using Serial Communication Module App 45 APPENDICES MELSEC Le serie
245. al register SW 5s used in the network module system since they are the data inherent to stations wo 7 Refer to Section 7 3 for the processing to be performed when the annunciator is tracked Remark Sooo ooo coco oer s x 0 Please use the following settings when changing the internal device settings Z So lt Z e Bit devices including timer retentive timer counter Se f F F 7 OS Multiples of 16 of the beginning device number ES Transfer range is setin 16 point units e Word device Set in 1 point units z eeseeeseecoeceec oe eoeaeeeoeoceeeeceeoeeeeoeeaeaeececeoceac eee eeee eee ea eae ee ee 8 3 ui a oc E 5 5 Tracking Function 5 79 5 5 3 Tracking Data D REDUNDANT SYSTEM FUNCTIONS Mi aL 20 fel ceries 2 Changing the Internal Device Settings Internal device settings are changed in the following cases Table5 45 Internal Device Settings Change Objective Tracking Setting e Change the settings so that only the devices actually hoe used will be tracked e To shorten tracking time i f f e Divide the tracking data range into multiple blocks and change the tracking timing for each block e Set the file register or annunciator to tracking blocks No 1 to 64 e Change the settings so that the tracking trigger of To add file register or annunciator See tracking block No 1 will be turned on and off manually e Program tracking timing to any a os ne e Divide the
246. am to execute that instruction again after system switching Table7 1 Instructions Requiring a Certain Number of Scans W i Ter Instruction Execution g o Instruction Classification j i LG Symbol Completion Signal T Z Data processin SORT azo i Sort Present SES Instructions DSORT ce Character Strin eee Read COMRD Present Processing Other Convenient Write data to specified file SP FWRITE Present a Instructions Read data to specified file SP FREAD Present gt Instructions Dedicated to Intelligent Function Modules Present z2 Refer to the manual of the intelligent function module used for the instructions dedicated to 55 intelligent function modules ci ri D d 5 ep Pema oO zZ o eo g 03 ET EO TROUBLESHOOTING 7 1 Instructions Restricted in Use for Redundant System 7 gj PROGRAMMING CAUTIONS b Countermeasures Device No SB20 switching However note that the same instruction might be executed twice Example In the following program example when system switching occurs during execution of the REMFR instruction M201 ON in an MELSECNET H remote I O system the REMFR instruction is re executed by the new control system CPU module e System configuration MELSEC TA ories 1 The instruction that includes the complete signal can be executed again by the new control system CPU module if it has been suspended due to system Diagram 7 1 shows the syste
247. ame position of that of the control system CPU module l Setting the Reset Switch of the Standby System CPU Module to Neutral Position Set the RESET L CLR switch of the standby system CPU module from the RESET position to the l central position reset switch neutral position EJPOINT Start standby system Diagram 8 17 CPU Module Replacement Procedure When the standby system is powered OFF the control system CPU module develops STANDBY SYS DOWN error code 6300 continuation error After the replacement of the standby system CPU module is complete clear the error in the control system CPU module as necessary Refer to Section 8 2 for the error resetting method 8 3 Replacing Module in Redundant System 8 3 1 CPU Module Replacement 8 TROUBLESHOOTING MELSEG LAY series 8 3 2 Power Supply Module Replacement Procedure Z 1 Power Supply Module Rep
248. an program execution time the next tracking cannot z start until the current tracking is completed In this mode the scan time can be made shorter than in synchronized tracking mode However if system switching occurs the new control system CPU starts operation 7 E based on the tracking data of up to 2 scans before 30 1 tracking when program run time 2 tracking time Eg as Scan time Prepare Tracking Prepare Tracking Prepare Tracking data 3 data 1 data 2 3 fn rror occurrence I Control system Run a R 7 R v 2 u un un END END END END CPU module program 1 0 program 2 program 3 9 H _ Z a s ft SS o New Standby system 9 9 Non executed CPU module Send _ Send Send 4 Tracking 4 Tracking 4 Tracking processing 1 processing 2 processing 3 fe Receive _ Receive Receive Incomplete 2a woe Standby system 5 5 5 v z CPU module 0 Run program OES a E 928 N p3 a Oo New Control system CPU module Adjust Tracking Adjust Tracking data 1 data 2 Device data for new control system CPU module Diagram 5 52 Tracking Operation Timing When Program Execution Time gt Tracking Processing Time Ol W 12 gt no E zZ lt x a Zz Q W a 2 Z O O Z u 2 Tracking when program run time lt tracking time Scan time n Prepare Tracking Prepare Tracking Prepare Tracking a data 1 data 2 data 3 z g Run a g S Waiting 1 Run Waiti
249. and noise Create the program using the MELSECNET H so that it will not stop control even when the temporary communication error is detected For details refer to the following manuals L gt Corresponding MELSECNET H Network System Reference Manual PLC to PLC network L gt Corresponding MELSECNET H Network System Reference Manual Remote I O network 8 1 Troubleshooting Flow 8 TROUBLESHOOTING MELSEG LAY series 8 2 Error Clear In a redundant system the errors that continue the CPU module operation can be cleared The following methods for error clear are available in a redundant system Clearing the host CPU module error Clearing the standby system CPU module error by the control system CPU module This includes clearing the standby system CPU module error by GX Developer connected to the control system CPU module 1 Clearing Host CPU Module Error The host CPU module error can be cleared using a special relay SM50 and a special register SD50 a Procedure Error clear is performed according to the following procedure 1 Remove the cause of target error 2 Store the corresponding error code into a special register SD50 3 Turn special relay SM50 from OFF to ON 4 The target error is cleared If the error is cleared and the CPU module returns to normal the relevant special relay special register and LED return to the previous statuses If the same error occurs again after that it will be re regist
250. and standby system CPU module execute interrupt programs for the interrupt factors sent from a network module c When the Operation Mode is Debug Mode The control system CPU module executes an interrupt program for the interrupt factor sent from a network module 7 2 Cautions on Fixed scan Clocks Programs PROGRAMMING CAUTIONS MELSEC Eseries 6 Interrupt during Tracking Processing If interrupt is enabled El status during END processing when an interrupt is issued z during tracking processing the CPU will stop the tracking processing and execute the a gt interrupt program 9 Therefore both data of before and after interrupt program execution might be tracked Example The operations for interrupted 131 execution via an internal timer are shown in z Diagram 7 10 0 bs gt Q 10ms no Execute interrupt I I I program 131 z lt O Oo z xe Q x Execute Tracking E transfer process R O Tracking transfer of data after a executing interrupt program a 5 Pag Cancel tracking transfer process woe execute interrupt program 504 Z Tracking transfer of data before 8 Ee 5 executing interrupt program ce Diagram 7 10 Operations When Interrupt Is Executed by Internal Timer When execution of programs interrupted during tracking processing is not done a execute DI instructions then execute El instructions at step 0 before executing END A instructions as shown in the prog
251. ange Other than RUN and BACKUP Takes over the current status Takes over the current status VO 5 64 __ Input Continues execution Continues execution I O from to main base unit Output Continues execution Starts output O from to extension base Input Continues execution Does not execute input unit Output Continues execution Does not execute output Link to CPU Continues execution Continues execution MELSECNET H PLC to 5 aaah PLC network CPU to link Continues execution oes not execute refresh No change from before operation mode change Link to CPU Continues execution Continues execution MELSECNET H remote D i e reresh oes not execute refresh 1 O network CPU to link Continues execution aSr No change from before operation mode change Auto refresh to network module on main base unit Intelligent module to CPU Continues execution Continues execution CPU to intelligent module Continues execution Continues execution Auto refresh of network module on extension base unit Intelligent module to CPU Continues execution Does not execute auto refresh CPU to intelligent module Continues execution Does not execute auto refresh SB SW refresh MELSECNET H CC Link 5 4 Operation Mode Change Function Link to CPU Continues execution Continues execution CPU to link Continues execution
252. ar request command Remarks ON Receive data clear request M11 Receive processing ON Executing OFF Not executed M12 M15 Send processing Receive data clear request pulse ON Executing OFF Not executed ON Receive data clear request M16 Receive data clear request acceptance flag ON Receive data clear request acceptance M17 Receive data clear request completion flag ON Receive data clear request completion M18 Communication disable ON Communication disable M19 b I O signal 1 O signal OH side Communication enable ON Communication enable Table App 19 List of I O Signal Signal name Description Xn3 XnA Reception data read request ON Requesting read Xn4 XnB Reception abnormal detection ON Abnormal detection Yn1 Yn8 Reception data read completion ON Data read completed c Buffer memory When all of the receive processing send processing and receive data clear processing are not executed write 1 to the following address A84 168 Buffer memory address Hexadecimal decimal CH2 side Table App 20 List of Buffer Memory 14814 328 Buffer memory name Receive data clear request E POINT 1 When using the Q series C24 function version A restart the data communication when 100ms has passed after the buffer memory address A8H for CH1 148H for CH2 was changed from 1 to 0 2 Do
253. arameter Tracking Tra2 SFC Information SFC Program Execution Time 1 Fixed PIDINIT Instruction Execution a a 0 5 Fixed zZ ime Tra3 PID Control Instructions S PIDINIT Instruction 0 5 Fixed Execution Time Tra4 Device Data X14 X2 X3 Z Number of Program Steps X1 to X3 are calculated as follows X1 Processing time according to number of device points for tracking settings X1 D1 x K1 D2 x K2 D3 x K3 D4 x K4 ms X2 Processing time according to number of device ranges for tracking settings X2 E1 x K5 E2 x K6 E3 x K7 E4 x K8 ms X3 Processing time according to number of tracking blocks for tracking settings X3 F1 x K9 F2 x K10 F3 x K11 ms D1 to D4 E1 to E4 F1 to F3 and K1 to K11 are values used in Table9 3 9 1 Extension of Scan Time due to Tracking 9 3 Q PROCESSING TIME FOR REDUNDANT SYSTEMS Mi aL EC Kel ceries Table9 3 Counting Value of D1 to D4 E1 to E4 F1 to F3 and K1 toK11 Saat Countin unti Content Number e Value Symbol D1 Number of Tracking Device Points outside of Index Register K1 0 09x 103 D2 Number of Tracking Device Points for Index Register K2 0 15 x 10 Number of Tracking Device Points for Standard RAM File D3 K3 0 09x10 Register Number of Tracking Device Points for SRAM Card File D4 l K4 0 42x10 8 Register Ei Number of Tracking Device Ranges outside of Index Register K5
254. arts cyclic transmission New Standby System Network Module 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 Communicates with the control system when it is specified by external device Communicates with the standby system when it is specified by external device Ete Transfers a message to the standby system when it is Transfers message to the control system when it is specified by external device specified by external device CC Link Controls remote station and exchanges data with standby Receives data from remote station and exchanges data with system master station master station PROFIBUS DP Continues PROFIBUS DP communications Stands by and prepares for system switching Refer to each network module manual for details on a specific network module operation 5 3 The System Switching Function 5 51 5 3 4 Both Systems Operations After System Switching OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol wW wn gt 2 Zz lt j zZ W ve 7 2 Q oO 2 5 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS Mi aL 20 fel ceries 5 3 5 Specia
255. atmenapge Program Multi CPU Redundant Inspection Fundamentals System system Included in package QCPU User s Manual Hardware Design Maintenance and inspection QCPU User s Manual Function Explanation Program Fundamentals Cele JU Ce Hiio CPU Module User s Manual Hardware QCPU User s Manual Multiple CPU System QnPRHCPU User s Manual Redundant System Details Outline Confirmation of connection methods for power supply module base unit and I O module Details Outline d 3 Construction of the single CPU system confirmation of start up procedure and I O number assignment Details Construction of the multiple CPU system confirmation of start up procedure and I O number assignment aS Details Confirmation of the sequence program configuration and memory Details Confirmation of the functions parameters and devices of CPU module Details Confirmation of the troubleshooting and error codes Details OVERVIEW MELSEC LA series Table1 4 List of programming manuals of high performance model QCPU S Common Instructions PID control Instructions Ne oO Process control Instruction N 5 Structured Text w S wi gt O r
256. attached Not attaching the terminal cover could result in electric shock Be sure to ground the FG terminals and LG terminals to the protective ground conductor Not doing so could result in electric shock or erroneous operation When wiring in the PLC be sure that it is done correctly by checking the product s rated voltage and the terminal layout Connecting a power supply that is different from the rating or incorrectly wiring the product could result in fire or damage External connections shall be crimped or pressure welded with the specified tools or correctly soldered Imperfect connections could result in short circuit fires or erroneous operation Tighten the terminal screws with the specified torque If the terminal screws are loose it could result in short circuits fire or erroneous operation Tightening the terminal screws too far may cause damages to the screws and or the module resulting in fallout short circuits or malfunction Be sure there are no foreign substances such as sawdust or wiring debris inside the module Such debris could cause fires damage or erroneous operation The module has an ingress prevention label on its top to prevent foreign matter such as wire offcuts from entering the module during wiring Do not peel this label during wiring Before starting system operation be sure to peel this label because of heat dissipation Install our PLC in a control panel for use Wire the main
257. below L gt QCPU User s Manual Function Explanation program Fundamentals eeeeeeeceeeeoeaeseoeoe ee eee eeeeeseseee eee eeeeoe eee eaeeeoee7 eee ee A 16 HOW THIS MANUAL IS ORGANIZED Reference destination A reference destination or reference manual is marked A Chapter heading The index on the right side of the page shows the chapter of the open page at a glance 5 REDUNDANT SYSTEM FUNCTIONS a 2 Confirming system A System B dently system A and system B by checking ina SYSTEMA and SYSTEM B LEDs of CPU modules Tables idemily system A and system amp by Chocking the SYSTEM A and SYSTEM B LEDs LED Name Syster A System B SYSTEM A ON OFF SYSTEM B OFF ON Refer to the fotiowing manual for datmas on the CPU module LED QCPU User s Manual Hardware Design Maintenance and Inspection 3 Precautions Wren using the redundant system in the hackup mode Connect the tracking ostie to the contro system and the standhy sysiom CPU moduirs If bath systems are powered on without Ive tracking cable connected to the CPU Models the TRK CABLE ERR error code 6120 stop error will occur and the system cannot run ITRS CABLE ERR occurs at power on power of System A and System B then connect the tracking cable to the CPU modules and power the systems on again EIPOINT When sterling op a single basc sysiem ase the debug mode Refer to Section 5 1 3 for the debug mode
258. by ee E H E 5 system Control RUN i q Stop program H system f Execute program i cs ele i l Tracking cable J Loy n d 2 25 GX Developer 5 z mm Diagram 5 26 System Switching Operation by GX Developer cZ 0 Z 2 no E O 0 Z E Q Q ae N a 2 5 3 The System Switching Function 5 37 z 5 3 1 System Switching Method D REDUNDANT SYSTEM FUNCTIONS E POINT MELSEC TA ories 1 If SM1592 is not turned ON at the time of system switching executed from GX Developer the error dialog box as Diagram 5 27 appears If the error dialog box as Diagram 5 27 has appeared turn ON SM1592 and then execute system switching again from GX Developer W MELSOFT application i The system switching is not allowed Please switch the system again after turning ON the manual change permission flag 5M1592 lt E5 010a424b gt Diagram 5 27 Error Dialog Box Displayed on GX Developer b System switching by the system switching instruction SP CONTSW instruction When the system switching instruction is executed in the control system CPU module the system switching is performed at END processing after instruction execution 1 The system switching by system switching instruction is done in the following procedure eTurn on the Enable disable user system switching flag SM1592 in the control system CPU module Turn on the system switching instruction condition in the control system CPU m
259. c Refresh from network Module on Main Base Unit Network Module CPU Module Executes the function Auto refresh to network module on extension base unit CPU module network module Executes auto refresh Auto refresh from network module on extension base unit Network Module CPU Module 5 70 Executes auto refresh In Backup Mode Control System Standby System E amp E During Normal During Stop Error Executes system switching During Normal RUN and During Continuation Error During Stop During Stop Eror Does not execute the program When the setting is Enable tracking of signal flow memory Renews the old data into the signal memory flow data tracked from the control system CPU module When the setting is No tracking Holds the current status OFF Executes it Executes the check while the control system is running Does not execute it when the control system is in STOP status or has developed a stop Does not execute the check Does not execute Executes the function the function Executes the online program change in the control system Does not execute it in the standby system only Executes the function when control system has been rewritten Standby system rewrite only is not possible Inputs it Turns OFF output Y during system switching Does not execute output Y in the standby system Does not output it
260. cation Module APPENDICES MELSEC TAY series The program example of sending data by the on demand function is shown in Diagram App 29 For the I O signal is X Y80 to X Y9F PROCESSING TIME FOR REDUNDANT SYSTEMS X9E X9F pote eens ence cenneenaensneeansensnesannensane o ae 1 Initial setting program for Q series C24 N i TOP H8 H9 Kt K1 J Writing is not required when send data is set in units of bytes words X50 i 8 PLS MO J Pulse outputs send command a W Mo i J a 11 MOV H1234 DO MOV H5678 D1 J gt Sets send data TO H8 HOCOO DO Ko 7 Sets the buffer memory head Se MOV HOCOO D2 address where the send data a is stored and the data length 2 7 Program MOV K2 D3 MOV K4 D3 j when send data is set in units of words Sets the on demand buffer memory TO ne ky Re ne head address data length SET M1 J Turns ON the on demand data set flag M1 X9E X9F X80 X81 X82 Y80 E l 3m HHAH RST _Y20 Resets output signal for 7 checking operator RST Y21 SET Y80 Starts up the on demand send request RST M1 Turns OFF the on demand data set flag Yeo X80 E 42 SET Y20 Completed normally X81 R d SET Y21 J Failed Reads LED status and on demand FROM H8 H256 D4 K1 J execution result and checks the cause of error completion _ Address 2564 FROM H8 H201 D5
261. cations and part names and explains z connecting disconnecting the cable to from the CPU module 5 3 1 Specifications The tracking cable specifications are shown in Table3 1 z0 RE 2G Table3 1 Tracking Cable Specifications DE 3 QG30TR Cable Length 1 0 m 3 29ft 3 0 m 9 87ft 4 Purpose Connecting the CPU modules of a redundant system S Mass 0 15 kg 0 28 kg g Tightening Torque 29 4N cm z 3 2 Part Names W 52 Tracking cable part names are indicated here ee SoZ aes BEA System n N psen B System A Connector i oy System A Confirmation Mark a m lt L UJ 7 i l l Gaps 7 z2 System B Connector 36 ag ge System B Confirmation Mark g5 e Jo Connector Fixing Screw W E n gt N 29 Ax 2O Be lu W Pe ms oO Z 2 no 26 S5 act eC g z E Q Q ae N W a O oc E 3 1 Specifications 3 1 3 TRACKING CABLE MELSEC TA eries 3 3 Connecting and Disconnecting a Tracking Cable 1 Cautions when Connecting a Tracking Cable e Be careful not to step on the tracking cable e When laying tracking cables secure a minimum bending radius of 27 6 mm or more e If the bending radius is less than 27 6 mm a malfu
262. ccccccccccccccccccccccccccccccccccccc ccs cc ccc cccccecccco ccc ce see ceeccecosoececooccococcoooocls A 1 HOW TO USE THIS MANUAL eeseesesesocoosococoocococoococoooocococoosococoocococoococoeoococoeoosocoesosocseoesoosooo 1G HOW THIS MANUAL IS ORGANIZED ececcecececcccccccccccccccccccccccccccccccccccccssccccccccccccsccccccsccscccsccscces 17 GENERIC TERMS AND ABBREVIATIONS seseesesosocoooooocoooooooooooooooooosoooooosoooooosoosooosooooooosososoos A 19 CHAPTER1 OVERVIEW 1 1to1 22 1 1 Redundant System OVEViEWeececccccccccccccccccccccccccccccccc ccc ccccccccceccecc cco ceccescococcoccocoococce 1 10 1 2 Features COCO OOO OOOO OOOOH OOOO OOO OOOO OOOO OOO OOOO OOO OOOO OOO OS OOS OOOO OOO OO OOOO OOO OOOO OOOO OOO OOOO OOOOH OOO OOOO OOOO OOOOC 1 12 CHAPTER2 SYSTEM CONFIGURATION 2 1to2 18 2 2 Peripheral Device Configuration eeeeeeeeeeeeeseesseeeeeesoooooooooossocosocoocececccesecesecesececeoessesssess 2 10 2 3 Applicable Devices and Software ssseeeeeseseseseeseeeseecsocoooscoooosososocosososososososososcocococesesesoos 2 1 2 4 System Configuration Cautions POCO OOOOH OHO OOOO OOOO OOOO OOOOH OOOOH OOOOH OOOO OOOOH HOSES OOO OOOH OSO OOOO OO OOOOH OOO 2 14 CHAPTER3 TRACKING CABLE 3 1to3 4 3 1 Specifications 00000 000000000000000000000000000000000000000000000000000000000000000 0000000 00 crccvesecveseovescosooooee Z 1 3 2 Part Names ccoooooooooooooo00000000000000000000000000000000000000000000000000000000
263. cccccccccccccccccccccscees 5 133 REMOTE reset eecececccccccccccccccccccccccccccccccscves 5 1 33 Remote reset operation evccccccccccccccccvcccccccocs D 13936 Remote RUN eessescocoooo0000000000000000000000000000 5 133 Remote STOP eeccceccccccccccccccccccccccccccccccsceee 5 133 Restarting system A and System Beeeeeeeceeeceeeeee 4 12 Restrictions on online module change Hot SWAPPING seeceeceeccccccccccccccccccccsccscccccsece 2 7 REVISIONS cccccccccccccvccccccccccccccccccccsccccccsecece A O Running CPU modules eeeccccccccccccccccccccccccccsee 4 1 3 S SAFETY PRECAUTIONS eecccccccccccccccccccccccccces Same system network module No issuing system switching request erccccccccccccccccccccccooeee 5 53 SD 1588 ecccccococcococococo00000000000000000000000000000 5 53 SD 1589 eccccccccccccccccccccccccccccccccccccccccccccccceee 5 53 SD 1590 ecccccoccccocococo0000000000000000000000000000000 H 5 SD15Q5 ccccccccccccccccccccccccccccccccccccesccscceseees 5 114 SD15Q6 ccccccccccccccccccccccccccccccccsccccccsccccccees 5 114 SD1 6 00000000 00C OOOO OO OOO OOOO OOOO OOO OO OOOO OOO OOO OOOO OEOOOC 5 52 SD1 600 0000 000 0OCC OOOO OOOOH OOOO OOO OOOOOO OOO OOO OOOOOSOOOC 5 54 SD1 601 000000000 CC OOOO OOOOH OOOO OOO OOOO OOO OOO OOOOOOOOOC 5 54 SD1 602 0000 OOO OOOO OOOO OOOOH OOOO OOOO OO OOO OOO OOOO OOOOOC 5 54 SD1 61 0 000000000 CO OOOO OOOOH OOOO OOO OOOO OO OOO OOO OOOO OOOOOC 5 54 SD 1709 eoccecenccccsseccccccncccc
264. ccccccse 5 1 15 Module initial settings coocooooooooooooo000000000000000000 Q CPU module RESET L CLR switch settingseess 4 9 CPU module RUN STOP switch settings essses 4 9 Modules applicable to redundant system eeseeseee 2 11 Modules that can be mounted on a remote 1 D station eeccccccccccccccccccccccccccccccccccccccccoccccs 2 13 Mounting MOUIES eececccccccccccccccccccccccccccccccccss 4 4 N Network module eecccccccccccccccccccccccccccccccccevccee 2 15 New control system ccocoooooocooooooo00000000000000000 N 20 New standby system ccooooooocoooooooooo00000000000000 20 0 Operating status consistency check settingse 5 19 Operation MOE eeecccccccccccccccccccccccccccccccccccccee H Q Backup MOE eeccccccccccccccccccccccccccccccscsccccces H Q Debug MOE ecccccccccccccccccccccccccccccccccccscccse 3 Separate MOE eececccccccccccccccccccccccccccccccccee H Operation mode change coococooooooooo000000000000000 57 Operation mode change procedure eeeereeeeeeeeeeee 5 58 Operation status consistency Check seereseeeeeeeeee 5 18 Operations when changing operation mode 5 64 Other system diagnostic error eeeeseeeseeeeeseseeesee 5 54 Overview POCOOH OOOOH HOO OOOO OOOOH OOO OOOOOO HOO OOOOH OOOO OOOOOS 1 1 P Pairing Settings and relevant CPU modules esses 2 5 Parameter valid drive settings consistency CNECK ecccccccccccccccccccccccccccccccccccccccccccccccvcccse OA Peripheral device configuration eeeseeseeeeseeeeeeeeee 2 10 PI
265. ccccoccccccccccccseesee 5 33 Control system cococccocccccococcooocoooooooooo00000 20 5 5 Control standby status flag SM1515 esecseseeseeees 5 7 Control standby status flag SM1516 esecseseeseeees 5 7 D Debug MOE evccccccccccccccccccccccccccccccccccccccccoee 5 3 Determination of control system and standby system coooooooooooooooo000000000000000000000000000000000000 FF When only one system starts Upereeeseeeeceecceeee 5 7 When system A and system B start up simultaneously eccccccccccccccccccccccccccccccccccocoes DG When system A Starts up first eeceecceeceeccceeeeees 5 5 When system B starts Up first sesreseseseeseseceeves 5 6 Determination of system A system B eeeeeeeeeeeeeees 5 3 Disconnecting a tracking Cable ssesssseeeseseeeseseses 3 4 Display of Write to PLC screen coeceeeseeececcececeee 4 4 1 E Enforced ON OFF of external I O ssessesesseseeeee 5 129 Error Check ecccccccccocooooooooooo0o00000000000000000000 _ 2 Error code 6120 ceccccccccocococcccccocococccoccococooocooooooo 5 4 5 8 G200 cccccccccccccccccccccccccccccccccccccccccccscoccoses 33 6210 ecccccccccccccocccocccococcocccooccoocooooooo00000 N 33 Error details window eecccccecccccccccccccccccscscscvese 5 33 Error detection processing ccocooooooooooooo00000000000 D_25 Extended scan TIME eeccccccccccccccccccccccccccccccccses Q 2 F Features cecccccccccccccccccccccccccccccccccccccccccccccccs 2 File consistency CHECKeccccccccccccccccccccccccccccccee 5 17
266. ceccccececccceeceeeolee 5 23 Standby system error detection disable flag at system switching ccocoooooooooooooo000000000000000 55D System switching enable disable flag from network module eecececccccccccccccccccccccccccccvcees B 52 Special relays for memory copy eeeeeeeeeceeeeeeees 5 114 Special relays for system Switching sereeeeeeeeeeeeee 5 52 STANDBY eocccccccccccccccccvccccccsccccccscccccccoceeees 5 33 Standby system eo cccccccccccccccccccccccooccccccoes 20 5 5 Start MOE ecccccccccccccccccccccccccccccccccccccecccceces 5 98 Hot sStart mode ecccccccccccccccccccccccccccccccccvcees 5 29 Initial Start MOE ceeccccccccccccccccccccccccccccccccee 5 09 Starting up GX Developereeececececccccccccccccccecees 4 10 Synchronized tracking MOE ecccccccccccccccccccccces 5 94 System A secccccccccccccccccccccccccccsccccccscsccces AO 5 3 System A discriminating flag SM1511 esesceesseeee 5 4 System B cccccecccccccccccccccccccccccccscccccccceess 20 5 3 System B discriminating flag SM1512 esesceeseeeee 5 4 System configuration evcccccccccccccccccccccccoccccscccs D Communication via CC Link eccecccccccccccccccccces 2 8 Communication via MELSECNET H PLC to PLC network eccccccccccccccccccccccccccccccccccccoccecs 2 5 Communication via MELSECNET H Remote 1 O NETWOrK eecceccccccccccccccccccccccccccccccccccoccccs 2 6 Communication with a Host OPS PC etc esses 2 4 Redundant System cooocooooococoocoooooo0000000000000 2 2 System configuration cautions
267. ceries c Special Relays Table5 46 shows the automatically transferred special relays a Special relays are only transferred in Backup Mode 2 i lo Table5 46 Automatically Transferred Special Relays Number Name Number ETT Startup watchdog timer for step transition SM90 to SM99 p g P SM701 Number of output characters selection 3 Emabled only when SFC program exists E SM202 LED OFF command SM702 Search method e SM206 PAUSE enable coil SM703 Sort order E SM210 Clock data set request SM710 CHK instruction priority ranking flag o SM213 Clock data read request SM715 El flag SM250 Max loaded I O read SM722 BIN DBIN instruction error disenabling flag PID b ing f lat SM254 All stations refresh command SM774 oss processing ae wy derivative a Selection of link refresh processing during COM SM255 to SM257 MELSECNET H module 1 information SM775 ee ee ge g instruction execution x SM260 to SM262 MELSECNET H module 2 information SM776 Enable disable local device at CALL SM265 to SM267 MELSECNET H module 3 information SM777 Enable disable local device in interrupt program PID bumpless processing for incomplate SM270 to SM272 MELSECNET H module 4 information SM794 umpless processing for Incomp derlvative z SM1500 c b SM321 Startup stop SFC program Hold mode S IN S OUT instruction Paz SM1501 m S 5 SM1520 to aga SM322 SFC program start status
268. ck And Tracking Trigger D REDUNDANT SYSTEM FUNCTIONS 5 88 MELSEC TA ories c Default Tracking Block Setting When the tracking settings are not made default settings devices will be set to tracking block No 1 based on the Default Tracking Range in Table5 44 XO to X1FFF YO to Y1FFF MO to M8191 Table 5 42 Default Transfer Range is set WO to W1FFF ZO to Z15 Diagram 5 50 Tracking device default settings internal device block setting d Caution When Dividing Into Multiple Blocks 1 When 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 5 5 Tracking Function 5 5 5 Tracking Block And Tracking Trigger D REDUNDANT SYSTEM FUNCTIONS MELSEC LA series 2 Tracking Trigger a Tracking Trigger Overview i A tracking block trigger is a special relay that determines whether to track the z multiple blocks of internal device data Tracking block triggers are assigned to each tracking block 3 Table5 49 When executing tracking turn on the tracking trigger that
269. cked in the PLC diagnostics of GX Developer The error history is backed up by the battery even if the PLC is powered off Redundant CPU Operation upon an error detection a Operation Mode when detecting an error When detecting an error through the self diagnostics the redundant CPU operates in the following two ways 1 Stop of redundant CPU operation Upon an error detection the redundant CPU stops the operation and performs system switching The redundant CPU holds all outputs Y that have not been assigned to the main base unit while it processes the outputs Y that have been assigned to the main base unit according to Output Mode on Error Detection of the PLC parameters I O assignment settings as shown below e Turns off all output of modules set to Clear Output default Device memory output Y is held e Output of modules set to Maintain output is held Device memory output Y is maintained 2 Continuation of redundant CPU operation Upon an error detection the redundant CPU executes all programs other than the program instruction where the error occurred 5 1 Basic Concept of Redundant System 5 25 5 1 5 Self Diagnostics Function OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol wW wn gt 2 Zz lt j zZ W oe 7 2 Q oO 2 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING
270. cking cable connector to the CPU module with screws Section 3 3 Is the SYSTEM A B LED lit Power off the standby system x Disconnecting the tracking cable from the control system and standby system CPU modules gt gt Section 3 3 Are there bent pins on the tracking cable connector YES Connecting the tracking cable connector to the control system and standby system CPU modules L Section 3 3 8 8 8 1 Troubleshooting Flow 8 1 3 When the SYSTEM A B LED is flashing Completed 8 TROUBLESHOOTING MELSEG LAY series 2 u gt oc gt Power on the standby system o rA Is the SYSTEM A B 2 LED lit 4 Zo Replacing the tracking cable Z LF Section 8 3 8 nO Reset the errors of the control system and standby system CPU modules R LF Section 8 2 z z Clear the control system CPU lt module errors lt _ 3 Section 8 2 5 oO x Completed m Is the SYSTEM A B LED lit up solid green a cn E p55 204 aza Replace standby system s CPU 6 ES module lt gt gt Section 8 3 1 TER Clear the control system CPU module errors 3 Section 8 2 Hi n a a 28 Is the Ze SYSTEM A B YES a2 LED lit up solid cc ik green W D Replace control system s CPU g module gt Section 8 3 1 z9 85 Be lu W Clear the control system CPU Te
271. cocscscnssccseesccceees 5 108 Self diagnostics at startup of redundant CPU s 5 27 Self diagnostics FUNCTION ceccccccccccccccccccccccccceee 5 25 Separate MOE ecececccccccccccccccccccccccccccccccccccee Setting the debug MOE eccccccccccccccccccccccccccecee 5 13 Settings of operation mode for error OCCUITENCE eeccccccccccccccccccccccccccccccccccccccccceces 2 SEC data ecccccccccccccccccccccccccccccccccccccccccccceses 5 89 Signal flow memory eecccccccccccccccccccccccccccooccces 5 8 SM 159 cccccccccccccccccccccccccccccccccccccccccccccccceee 55D SM1591 cccccccccccccccccccccccccccccsccccccccccecccccccc00 5 52 SM 1595 cccccccccccccccccccccccccccccsccccccccccccccccces 5 114 SM 15QGcccccccccccccccccccccccccccccsccccccccccccccccces 5 114 SM15Q7 cccccccccccccccccccccccccccccsccccccccccccccccces 5 114 SM 1 70Q ccccccccccccccccccccccccccccccccccccccccccccccces 5 1 8 S171 Qccccccccccccccccccccccccccccccccccccccccccccccces 5 108 SP CONTSW instruction eeecsccccccccccccccccsvcecee 5 38 Special register Automatically transferred special registers 5 84 Error COMMON information eececeeccccccccccccccceee B 52 System switching disenabling conditionssssss 5 52 Special registers for system switching esesesseeeeee 5 52 Special relay Automatically transferred special relayseesess 5 83 SM1 51 D ocoooooooooooooooooooo0o0000000000000000000000000 5 7 SM1 51 Goeocooccocoooooocoooooocoooo00000000000000000000000 5 7 SM609 Coc ccccccccccccccccccccccc
272. comments Available information and comments are displayed etc can be confirmed using GX Developer 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 switching Operation mode change by redundant operation of GX Developer Operation mode change using switches of bus switching module A6RAF CPU module damage external output Power supply module error contact output System management module AS92R CPU ALRAM WDT contact point output Q6PU N A Applicable SWLIIVD GPPQ N A Applicable GX Developer Version 8 18U and later is applicable SWOD5C GPPW and later is applicable Programming Tool MX Links N A MX Monitor Substituted with MX Component PC side Applicable MX Chart application program correction necessary Connection Port RS 232 USB Appendix 1 Comparison of Q4ARCPU and QnPRHCPU RS422 RS 232 RS 422 converter App 3 PROCESSING TIME FOR REDUNDANT SYSTEMS APPENDICES INDEX APPENDICES MELSE LA series Table App 1 Comparison of Q4ARCPU and QnPRHCPU Redundant Systems Continued Item QnPRHCPU Redundant System Q4ARCPU Redundant System Instruction Restrictions Instructions shown in Table1 2 are inapplicable Special Relay Some
273. contents of program memory Z 65 TS TROUBLESHOOTING 5 6 Writing To The Both Systems Using GX Developer 5 109 5 6 2 Program Change While CPU is Running D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series d Processing when the target programs are different between the control system and standby system CPU modules If the target programs are different between the control system and standby system CPU modules it will be written to the control system CPU module only If this happens the error dialog box in Diagram 5 69 will appear on GX Developer MELSOFT series GX Developer LD Write during RUN will be cancelled because FILE DIFF 6000 has occurred in the standby system Diagram 5 69 Error Dialog Box Displayed on GX Developer e Access to programs being changed online The programs being changed online cannot be accessed by GX Developer If programs in RUN write by GX Developer are accessed the error dialog box in Diagram 5 70 will appear on GX Developer E MELSOFT application i This peripheral device or another peripheral device are operating online change function J Please execute it again after it completed online change Function lt E5 010a424c gt Diagram 5 70 Error Dialog Box Displayed 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 onlin
274. control system CPU module TROUBLESHOOTING 5 1 Basic Concept of Redundant System 5 17 5 1 4 System Consistency Check D REDUNDANT SYSTEM FUNCTIONS MELSEC TA ories 2 Operating Status Consistency Check a Check points The operating status consistency check means checking the CPU module operating status RUN STOP PAUSE Standby system Control System Control system J in im ao O g System switching activated Pik Section 5 3 i system switching causes Tracking cable f Operating status Operating Status RUN lt is equalized gt Operating Status RUN System switching allowed Diagram 5 12 Operating Status Consistency Check b Inconsistency Errors Table5 13 shows inconsistency errors that occur when the operating statuses are inconsistent Table5 13 Inconsistency Errors Execution Conditions Error Description e When both systems are powered ON simultaneously The following stop error will occur in the control e When both system CPU modules are unreset system and standby system CPU modules RESET L CLR switch is set to the neutral OPE MODE DIFF error code 6020 position simultaneously e When one system starts up after the other e During normal operation The foll
275. control system through a system switching instruction Appendix 5 Method for Starting up the Previous Control System App 25 APPENDICES MELSEC TE eries POINT Create a system switching program while paying attention to the following points e 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 e 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 will occur 2 When Mounting a Network Module on the Main Base Unit Confirm that the network module has started up and create a program that executes the SP CONTSW instruction as shown in Diagram App 20 System Configuration network network System A module System B module Co 16os Tracking cable Diagram App 19 The system when a network module is mounted on the main base unit App 26 Appendix 5 Method for Starting up the Previous Control System APPENDICES MELSEC TAY eerie Program Example SM1519 o CALL Ping Makes the subroutine program P100 execute when the previous control system is the system B GOEND Jumps the
276. coooooooooooooooooooooooooooooooooooooo000000000000000000000000 8 27 8 3 Replacing Module in Redundant SGystEemMe eseceeeccccceccccccccccccccccoccccccoccccccoccosccoccoscocososoooo 8 31 8 3 1 8 3 2 8 3 3 A 12 CPU Module Replacement SOOO OOO OOOH OOO OOO OOOOH OOO OL OOOOH OOOO SOHOO OOOO OOOO OOOOH OOOO OOOOH OOOO OOOOH ODES 8 31 Power Supply Module Replacement ProcedurE secececccecccoccococoocoo0000000000000000000000000000000 8 33 Redundant Power Supply Replacement Procedure C0000000 000000000000000000000000000000000000000000 8 35 8 3 4 8 3 5 8 3 6 8 3 7 8 3 8 8 3 9 8 3 10 I O Module Replacement Procedure eecccccccccccccccccccccccccccccccccccccccccccccvcccccccccccosososoes 3 365 Network Module Replacement ProcedurEe ssccccccccccoocoooooo000000000000000000000000000000000000000 3 39 Main Base Unit Replacement Procedure ssccscsoccocoooooocooooooc0000000000000000000000000000000000 3 40 Procedure for Replacing Module mounted on the I O Station of Redundant Systemeseeeseeee 8 43 Replacement of Modules Mounted to Extension Base Unite eeeseeeesseeeeescececescoecccsocecessoe 3 44 Tracking Cable Replacement eeeeeeeeeeseeceecceoceecceccoocooceoceoceoccoccooceoceoceecoeccoccocceccoecee 3 45 Replacement Procedures of Extension Cable eccccccccccccccccccccccccccccccccccccccccccccccccccccoces B 47 CHAPTER9 PROCESSING TIME FOR REDUNDANT SYSTEMS 9 1 9 1to9 8 Extension of Scan Time due to Tracking coooooooooo
277. corresponds to each tracking No to execute tracking in the program fez b Setting Tracking Trigger for Tracking Block No 1 Z It is possible to make the settings at the tracking settings in the redundant 26 parameter settings so that the data tracking trigger SM1520 for tracking block No 1 will turn on automatically when power is turned on By default the tracking trigger for tracking block No 1 turns on automatically and automatically tracks the device data in tracking block No 1 g Table5 49 Tracking Triggers Z Set By Number Description Default User or System When setting batch of internal devices at the ci tracking Sa Turns on at the time of power ON reset STOP to ws 5 l RUN RZ OFF Disable z ors i When the detailed device settings are made at the ae SM1520 Tracking Block No 1 Tracking Trigger Tracking tracking settings System EiS ON Enable User Tracking e The trigger urns on arhe time of power ON reset 5 STOP to RUN if tracking block No 1 is set to be tracked in the automatic tracking parameter E Turn off if tracking block No 1 is set to not to be d tracked in the automatic tracking parameter Z z SM1521 Tracking Block No 2 Tracking Trigger Sin SM1522 Tracking Block No 3 Tracking Trigger g5 SM1523 Tracking Block No 4 Tracking Trigger SM1524 Tracking Block No 5 Tracking Trigger SM1525 Tracking Block No 6 Tracking Trigger a SM1526 Tracking Block No 7 Tracking Trigger 2 SM1527
278. curs In this case review the communication path and restart the communication Network Parameter Settings 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 to the CPU modules of System A and System B Refer to the following manual for network parameters lt 3 Q Corresponding Ethernet Interface Module User s Manual Basic Redundant settings K System B settings i 9 I Issue system switch in Cable disconnection timeout Station number and mode setting System A Cable disconnection timeout setting 2 0 sec 0 0sec 30 0sec Station number Issue system switch in communication error Mode System switching settings when communication error occurs Fixed buffer Station number and mode setting System B Protocol Open system Fixed buffer communication procedure 7 Station number 2 Hea Active Send gt Procedure exist gt Procedure exist Mode Online 2 v Procedure exist IP address settings x l Input format DEC z I Enable auto open UDP pott System A I Enable GX Developer UDP c
279. d Send m Send __ Send __ se 4 Tracking 4 Tracking 4 Tracking Eg processing 1 processing 2 processing 3 ae Receive _ Receive _ Receive END END 0 END 0 Run program 1 se Run program 2 Run program 3 Run program 4 l Standby system a O ee m lt CPU module E Adjust Tracking Adjust Tracking lt data 1 data 2 i Diagram 5 56 Tracking Operation Timing in Separate Mode i oc 2 lt woe EE ZEU ane Ol W 2 gt 2 E zZ lt q Zz Q W a 2 Zz O S Z u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 5 Tracking Function 5 97 5 5 7 Tracking Mode D REDUNDANT SYSTEM FUNCTIONS MELSEC LA series 5 5 8 Device Data Used By The New Control System When the tracking from the control system CPU module is complete the standby system CPU stores the received tracking data into the specified devices sequentially When system switching occurs the new control system CPU begins operation based on the received tracking data which varies depending on the reception condition at the time of system switching Table5 53 shows device data used by the new control system CPU module depending on the tracking data reception condition Table5 53 Device Data Used by New Control System CPU Module Tracking Data Received Tracking Data Not Received R R Receiptopm of Tracking Data Tracking Data 1 Completed System Sw
280. d intelligent function module function version C mounted on the MELSECNET H remote I O station while power supply is ON e Function to replace the power supply module while the system is operating when the system uses the redundant power main base unit 5 2 FUNCTION LIST 5 31 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol W wn gt 2 Zz lt j zZ W ve 7 2 Q oO 2 5 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS Mi aL 20 fel ceries 5 3 The System Switching Function Switching Between The Control System And The Standby System This section explains the executing system switching while the redundant system is running execution timing execution possibilities operations of control standby system CPU modules and relevant precautions 5 3 1 System Switching Method 2 methods of system switching are available automatic system switching and manual system switching that is performed by the 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 Table5 22 System Switching Method and the Applicable Operation Modes System Switching Method Description Ope
281. dant system can be mounted on remote I O stations in order to communicate with external devices 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 power supply system or if the power supply module fails This enables the faulty power supply system to be restored and power supply modules that have failed can be replaced even when the remote I O station power supply is on The power supply module can also be replaced for preventive maintenance etc when the remote I O station power supply is on 2 1 System Configuration 2 SYSTEM CONFIGURATION MELSEG Fl cries c Online Module Change Hot Swapping Using GX Developer The I O module mounted on a remote I O station including analog module of function version C can be replaced online hot swapping using GX Developer Refer to Section 2 4 for modules on a remote I O station that can be replaced online hot swapping using GX Developer N OVERVIEW wuts Remote Master Station Mutilexed Remote Sub master Station Zz z 5 System A System B r Cenirol Systeri Q35B Standby Svlein q358__ 1 Intellli refers to the Intelligent Function module m Ssi z l ElE S 2 Jalalelsl 8 s 2 z ejg SjajijE 2 In a coaxial bus system use double shielded
282. dby Control Standby System switching will causes system B lt Request by Network System System System System to become control system Module System Switching Control Standby Control Standby Startup as standby system Manual Using GX Developer System System System System 2 System System Switching b zo UPEN 4 neang OY Control Standby Control Standby 2 lt Switching System Switching Startup as standby system USE f System System System System SoZ Instruction azo BER W ane Table5 29 Operations When System Switching Cannot Be Executed Due to Error Other Than Stop Error in the Standby System 3 System Status After 2 System Status Before System eel F Switchin Control System Switchin System Switching Operation After System B Power 2 a Switching Condition g Condition OFF gt ON Sa System A System B SystemA System B ES 6 Stop Error Other Than Control Standby Standby Control Sarun as cohiroisvelen pZ Watchdog Timer Errors System System System System p E Control Standb Standb Standb Watchdog Timer E y Startup as control system System System System System Control Standb Standb Control pe A Hardware Failure 7 Startup as control system Automatic System System System System a System Control Standb Standb Control z2 y gt Power OFF 4 y Startup as control system Sy Switching System System System System ZS Control Standby Standby Control D m Reseting Startup as cont
283. ding to the error code stored in D20 RST Y80 d Turns OFF the send request signal X60 32 Y8E D Turns OFF the LED and clears the error code Diagram App 32 Program Example Appendix 6 Precautions for Using Serial Communication Module App 49 APPENDICES MELSEC Le series Appendix 6 10 BIDIN Instruction The following shows the device and buffer memory used in the sample program of receiving data by the bidirectional protocol communication 1 Device of PLC CPU Table App 45 Device Used in the Program Device No Application Remarks X30 Error code read command ON Error code read X60 Clear command ON Clear completion 2 W O signal Table App 46 List of I O Signal O signal Signal name Description Xn3 XnA Reception data read request ON Requesting read X nH1 F Watchdog timer error ON Module error occurred WDT error OFF Module being normally operated Yn1 Yn8 Reception data read completion ON Data read completed 3 Buffer memory Table App 47 List of Buffer Memory Buffer memory address Hexadecimal decimal Stored value CH1 side CH2 side 0 Normal completion 2584 600 2684 616 Data reception result 1 or more Abnormal completion error code Receive data count No receive dat 600 1536 A00 2560 Number of data for which Hl Hl Nu a 1 or later Number of receive data read is requested 6014 to 7FFy A01 to BFFy Data recei
284. dware Design Maintenance and Inspection REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol wW no gt 2 E zZ lt z Q W a 7 2 Q oO 2 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 1 Basic Concept of Redundant System 5 sAd 5 1 3 Operation Mode D REDUNDANT SYSTEM FUNCTIONS 5 12 MELSEC TA ories c Precautions 1 When the operation mode is changed with GX Developer while the redundant Y EJPOINT 1 system is running the operation mode will automatically change to the separate mode Refer to Section 5 4 for details on changing Operating Mode If either system is powered on again or either CPU module is unreset RESET L CLR switch is set to the neutral position in the separate mode system switching will not occur e If the control system is powered on again or unreset RESET L CLR switch is set to the neutral position it will start up as the control system again e If the standby system is powered on again or unreset RESET L CLR switch is set to the neutral position it will start up as the standby 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 Do not turn OFF the power sup
285. e Tracking cable Control and network automatic system switching eola e L ll N Ge Diagram 1 4 System Configuration for MELSECNET H PLC to PLC Network 1 14 1 2 Features 1 OVERVIEW MELSEC TAY series b MELSECNET H Remote I O Network MELSECNETHH remote I O stations can continue the operation even when control standby system switching occurs Section 6 2 2 OVERVIEW
286. e both system CPU modules judge it as the failure of the online program change for redundancy In this case both system CPU modules resume the consistency check between system A amp B suspended during the online program change Also the control system CPU module is set to accept a new request of online program change for redundancy When both systems are powered on 90 seconds are set to SD1710 as the default value Set the value within the range 90 to 3600 seconds When the setting is 0 to 89 seconds it is regarded as 90 seconds for operation If the setting is outside the allowed range it is regarded other than 0 to 3600 seconds for operation The waiting time for a start of online program change to the standby system CPU module is checked according to the SD1710 setting during online change of multiple blocks and online change of batch of files for redundancy 5 108 5 6 Writing To The Both Systems Using GX Developer 5 6 2 Program Change While CPU is Running 5 REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 7 Precautions a Corrective action when program memory capacity shortage occurs during writing a batch of files during RUN When writing a batch of files to program memory during RUN the working memory area unused area equivalent to the target files must be ensured in the program memory If the enough working memory area is not ensured in the program memory a batch of files cannot be written during RUN However if the nece
287. e make system A and system B parameters and programs consistent If inconsistent the FILE DIFF error code 6000 stop error will be detected by the consistency check between systems A and B Refer to Section 5 1 4 for consistency check between systems A and B 5 1 Basic Concept of Redundant System 5 1 3 Operation Mode D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 2 Separate Mode The separate mode is for maintenance program modification replacing the module z mounted on the main base unit etc without stopping control z In the separate mode different programs can be run in the control system and 3 standby system CPU modules a Enabling Disabling the Tracking Function In the separate mode it is possible to select whether the tracking function is 6 enabled or not in order to perform the tracking is Refer to Section 5 5 for the tracking function Bs no b Confirming the Separate Mode Confirm that the redundant system is running in the backup mode by checking the BACKUP LEDs of CPU modules Table5 6 Checking the BACKUP LED to Confirm the Separate Mode CPU Module LED LED Status TEPAGA Control Standby MODE BACKUP LED Name RUN CONTROL System System ERP SYSTEMA TRACKING CABLE USER SYSTEMB ON ON BAT BACKUP POOL amber amber Refer to the following manual for details on the CPU module LED lt gt QCPU User s Manual Har
288. e I O module MELSECNET H Remote I O network Serial communication module Remote O station Remote O station a GOT 1000 Series GOT 1000 Series GOT A900 Series GOT A900 Series CPU directly connected Computer link connected Diagram 6 34 GOT Connection Method Applicable to a Redundant System 6 42 6 3 Communication between the Both Systems CPU Module and GOTs 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series 6 3 1 When Connecting GOTs to a MELSECNET H Remote I O network For MELSECNET H network connection connect GOTs to a remote I O module or serial communication module mounted on a MELSECNET H remote I O network remote I O station OVERVIEW The GOT cannot be connected to the base unit of a remote 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 CONFIGURATION SYSTEM 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 connection connect the GOT to a serial communication module mounted on a remote I O stati
289. e Program Multi CPU Redundant Inspection Fundamentals System system QCPU User s Manual Hardware Design Maintenance and inspection QCPU User s Manual Function Explanation Program Fundamentals QCPU User s Manual Multiple CPU System QnPRHCPU User s Manual Redundant System Details Confirmation of connection methods for power supply module base unit and I O module d 3 Outline Details Construction of the single CPU system confirmation of start up procedure and I O number assignment Details Construction of the multiple CPU system confirmation of start up procedure and I O number assignment aS Details Confirmation of sequence program configuration and memory Details Confirmation of the functions parameters and devices of the CPU module Details Confirmation of the troubleshooting and error codes Details OVERVIEW MELSEC fA cries Table1 6 List of programming manuals of process CPU S Common Instructions PID control Instructions oO Process control Instruction s5 Structured Text w S wi gt O r QCPU Q mode QCPU Qmode QnPHCPU QnACPU QnACPU QnPRHCPU QCPU Q mode QCPU Q mode QCPU Q mode a Purmose
290. e Sub master Station 1 a Master D System A station System B Standby Master station ech Gakenu Q4ARCPU a Control System T Standby System Normal Normal Dorna T F a3 a Z a3 a station station Control a 6 a Bl Ble a Bl ale station 56 m had f bad ey BL Ii i e Jii ws al Bl Bly H E 2 E Bl Bl l BI gE lee 6 I Tracking cable PROFIBUS DP D n A GX Developer DP Slave DP Slave 2 S CC Link i Remote Intelligent __MELSECNET H Remote I O network Remote voj Bevis Tia station y Remote O station Siation Stallon oO gt zZ Sa a Remote Remote zn z ala 2 I O station I O station Efa 5 ONIS E O E3 G 9 5 5 O r EE S External device Si me 8 Diagram 6 6 Redundant System Network 3 a oc E 6 2 Redundant System Network Overview 6 i7 6 REDUNDANT SYSTEM NETWORKS 6 8 MELSEC Eseries 6 2 1 MELSECNET H PLC to PLC network In a redundant system the data link is continued through system switching even when an error occurs in the control system or control system network 1 Overview of Communication between Control System and Standby System Network Modules In a redundant system the control system network module carries out cyclic data com
291. e 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 illustrated below will appear if online program change is executed during the following e Standby system power is OFF e Standby system CPU is resetting e WDT error occurring on the standby system CPU e Tracking cable not connected or malfunctioning MELSOFT series GX Deyeloper Diagram 5 71 Error Dialog Box Displayed on GX Developer 2 Changing programs being accessed by the other GX Developer online The error dialog box Diagram 5 72 will appear if online program change is executed to programs being accessed by the other GX Developer MBA SUE applica jay i Procesoro Em progress From another papheral device Please wakt urri the other proceszang ie completed then execute ogan SEROL Cay Diagram 5 72 Error Dialog Box Displayed on GX Developer 5 110 5 6 Writing To The Both Systems Using GX Developer 5 6 2 Program Change While CPU is Running D REDUNDANT SYSTEM FUNCTIONS g Online program change in Separate Mode h MELSE TE ories 3 Changing programs being accessed by the other GX Developer online The error dialog box in Diagram 5 73 will appear if online program change is executed to the CPU module during system switching or operation mode change OVERVIEW Ml MELSOFT application O Communication trouble or system switching was
292. e reserved for comminication 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 setting for incomplete derivative SD1500 to SD1501 Basic period SD1649 Error number reset on standby system CPU D1710 Waiting time for online program change standby system 5 5 Tracking Function 5 5 3 Tracking Data D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 5 5 4 Tracking Data Settings Make the tracking data settings at the tracking settings in the redundant parameter a settings using GX Developer w M lo If the tracking settings are not made the tracking device setting will be the Internal device block setting default and tracking will be executed based on the default settings 1 Redundant p rameter E Operation settings 2 2 Tracking device settings E x Internal device block setting x Internal devices include X Y and other internal devices a ie Signal flow memory tracking setting No tracking i All tracking device capacity K word 6 Enable tracking of signal flow memory Device total increases 16K word 3 Device detail settings m Tracking block No e Device range settings 1S g 4 7 Device total j Maximu
293. e s special functions Sold separately Q Corresponding Ethernet Interface Module User s Manual Basic This manual contains information on the specifications of the Ethernet module the procedures for data communications with external devices circuit connection open close fixed buffer exchange random access buffer exchange and the troubleshooting Sold separately Q Corresponding Ethernet Interface Module User s Manual Application This manual explains the e mail function of the Ethernet module the PLC 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 FTP server etc Sold separately Q Corresponding MELSEC Communication Protocol Reference Manual This manual explains the communication methods and control procedures through the MC protocol for the external devices to read and write data from to the CPU module using the serial communication module Ethernet module Sold separately CC Link System Master Local Module type QJ61BT11N User s Manual This manual describes the system configuration performance specification function handling wiring and troubleshooting for QJ61BT11N Sold separately PROFIBUS DP Master Module User s Manual This manual describes the system configuration performance specification function handling wiring and troubleshooting for QU71PB92V Sold separately Manual Number
294. ecsecsosoose ADD 28 Appendix 6 1 Appendix 6 2 Appendix 6 3 Appendix 6 4 Appendix 6 5 Appendix 6 6 Appendix 6 7 Appendix 6 8 Appendix 6 9 Appendix 6 10 CSET Instruction eeeeeeesesececcecececccococeococooocsososooosososososososeoossosesosesecesseses ADL 29 UINI Instruction seeeeeeeeeeeeeeececeeccccecececccccccccccceesceesessecescccscscsssoseceseseseoeee ADD 34 INPUT Instruction eeeeeeeeeeesesosesososocecocececocececececceoecosssesesososososssssoseseseseee ADD 37 PUTE Instruction eeeeeeseeesesesececececocecocococcccccccccecececessosesssssssssssssossosossssee ADD 38 GETE Instruction eeeeeeesesececcececceococeccocooocosooooosoosososososososcosssscesosesosesesese ADD 40 ONDEMAND Instruction seeeseeeeececeeeececoococoosooooooosososososososcocecosesosecesesesese ADL 42 OUTPUT Instruction eseeeeeeeeeeeccceccocececooosoooooooooossooososososososososesossscossesseee ADD 44 PRR INStrUCtion eeeeeeeeeeeeeseseeosesoscoosocosocococococecccccccecceceseoososososssssssesosssoss ADD 46 BIDOUT Instruction eeeeeeeeeeseeecesesccececccoecooososocosooossoosososososooscesososeseseseee ADD 48 BIDIN Instruction eeeeeeeeeeeeeeccecececececececoecesosososososssosososososocososesoseseseseseee App 50 Appendix 7 Restrictions on Communication via Module Mounted to Extension Base Unit eeseeeeeeeesee App 51 INDEX INDEX 1 to INDEX 3 A 13 ABOUT MANUALS The following manuals are also related to this product In necessary order
295. ecting the tracking cable Tightening torque 29 4 Necm Connector Screws Flathead screwdriver Diagram 4 6 Fixing a Tracking Cable Connector 4 8 4 2 Wiring PROCEDURE FOR STARTING UP A REDUNDANT SAE MELSEC fAfssries 4 3 Module Initial Settings Make the switch settings for the CPU module and network module Refer to the manual for the network module used as the settings vary according to the model OVERVIEW 1 CPU Module RUN STOP Switch Settings Set the RUN STOP switch of CPU module to the STOP position 2 CPU Module RESET L CLR Switch Settings Set the RESET L CLR switch of CPU module to the reset switch neutral position CONFIGURATION SYSTEM CPU module Power Switch STOP RUN amp lt _ A TRACKING CABLE RESET L CLR Switch RESET _L CLR Diagram 4 7 CPU Module Switch Positions and Settings Make sure to operate the RUN STOP switch and the RESET L CLR switch by hand to make the settings If these switches are operated by the screw driver or other tool this can result in damage A W n gt n 2 A lt a Zz a W oc aj r lt ws oi ze aw 4 4 Confirming that the Power Supply is ON a 7 1 Powering on the system Ea Check the power line and power supply voltage of the power supplies of the power Efa supply modules of the main base units and extension base units in systems A and B ae and turn ON p
296. eeeae ee eee 6 5 1 4 System Consistency Check D REDUNDANT SYSTEM FUNCTIONS Mi aL 3G Kel ceries 1 File Consistency Check a Check points i The file consistency check means checking the following files at system switching z as shown in Table5 11 Table5 11 Target Files and Check Contents z e Checks the parameters stored in the drive set as parameter valid lt drive PLC parameters redundant parameters network ze Parameters parameters and the intelligent function module parameters set with 26 GX Configurator e Checks the remote password stored in the program memory e Checks the program file set in the PLC parameters program T Programs settings a e The password set in the password registration is irrelevant 9 e Checks the initial device value file set in the PLC parameter PLC file Initial Device Values settings E e The password set in the password registration is irrelevant Area for Online Change of Checks the memory capacity of the area for online change of multiple Multiple Block Write blocks set during formatting 5 g b Inconsistency Errors See Table5 12 shows the file inconsistency errors occurred when the target files are SES inconsistent a oo Ol Table5 12 File Inconsistency Errors Execution Conditions Error Description e When both systems are powered ON simultaneously e When both system CPU modules are unreset RESET L CLR switch is set to the neutral position simultaneou
297. eeeeeeeeeeseeeeeeeee 2 14 Modules that can be mounted on a main base LUMiteccccccccccccccccccccccccccccccccccccccccccccce 2 1 5 Number of slots occupied by a Redundant Restrictions on online module change Hot SWAPPING serceeceecceccccecsecscccecvesvcccccees 2 17 Restrictions on use of extension base units 2 15 System A system B configuration eeeeeeeeeeeeee 2 15 System fault information eecccccccccccccccccccccccscces 5 54 System switch reSultseececccccccccccccccccccccccccecces B 54 System switching by the system switching INSTFUCTION eecccccccccccccccccccccccccccccccccccccccccccoes H 3 System switching condition eecececccccccccccccccccvcee 5 53 System switching dedicated command parameter ooooooooooooooooo0000000000000000000000000000000 FA System switching disenabling Conditionesssssseeee 5 53 System switching during online program change ccoooooocooooooooooo000000000000000000000000000000 D 1 7 System switching execution possibility sess 5 43 5 48 System switching execution timinge eeeeeeeeeeeee 5 42 System switching FUNCTION ecccccccccccccccccccccccccee 5 32 System switching Method ecceccccccccccccccccccccccses 5 30 System switching Precautions eercceceeececeeceeeeeee 5 55 System switching PIiOrity seeecceeccecccccccccccccccccee 5 40 System switching requested by the network MOIUIE eecccccccccccccccccccccccccccccccccccccccccvcvcvcces 3h System switching using GX Developer esessseeeeee2 5 37 System switching when a fault occu
298. een disconnected during maar normal operation the LED will x z Zz flash until B system s EZA connector is reconnected S reo Vv ane Is the standby system s power NO turned ON m n a a Turn ON the standby system power z2 T Be ag A wW D 4 GEE Has the standby system s CPU module reset been canceled im 9 Cancel the standby system s CPU 2 module reset A g ZO 3E W W 4 EA 1 0 Z Zg 26 E O o z E Q fe ae n W a gt 2 8 1 Troubleshooting Flow 8 15 8 1 6 When System Switching has failed 8 TROUBLESHOOTING 8 16 Is the standby MELSEC TA ories YES Stop error system CPU module ERR LED flashing NO For the standby system NO Connect GX Developer to the standby system CPU module use the System Monitor PLC diagnostics to confirm the problem area and resolve the problem Restart the standby system cycle the standby system power or reset the standby system CPU module has a power OFF reset or stop error occured Is the BACKUP LED ON solid green 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 Green Backup mode Ld Use GX Developer to change the running mode to backup mode
299. eing normally WDT error operated Yno Yn7 Transmission request ON Requesting transmission 3 Buffer memory Table App 44 List of Buffer Memory Buffer memory address Hexadecimal decimal Stored value GHZ side 0 Normal completion 2574 599 2674 615 Data transmission result 1 or more Abnormal completion error code Transmission data count 0 No designation 400p 1024 8004 2048 designation 1 or more Number of send data 4014 to 5FFy 801 to 9FFy Transmission data Data to be sent to an external 1025 to 1535 2049 to 2559 designation device App 48 Appendix 6 Precautions for Using Serial Communication Module APPENDICES MELSEC TA eerie The program example of sending data by the bidirectional protocol communication is shown in Diagram App 32 For the I O signal is X Y80 to X Y9F PROCESSING TIME FOR REDUNDANT SYSTEMS iH KA EK 44 44 a H MOV ABCDEFG D1 MOVP HOAOD D15 Sets the send data and the number of send data MOVP K5 D10 J APPENDICES K6 Writes the send data and the number of send TOP H8 H400 D10 data to the buffer memory SET Y80 Turns ON the send request signal Y80 7 after the data is written X80 23 RST Y80 jj Turns OFF the send request signal x lt X81 _ Reads the send error code a 25 FROMP H8 H257 D20 KI Check the error description and take corrective 2 action accor
300. el Ey ENE z e gea fest Remote I O station Remote I O station station No 2 station No 3 Diagram 6 18 Error Detection at Cable Disconnection Table6 2 shows the transmission possibilities when a disconnection occurs at Point A only and when a disconnection occurs simultaneously at Point A and Point C Table6 2 Transmission Possibilities when Disconnection Occurs at Point A and Point C At Point A Only At Points A and C System A CPU System B CPU System A CPU System B CPU Module Module Module Module 1 Station O G x O 2 Stations O O O x 3 Stations O x O Possible x Not Possible 6 20 6 2 Redundant System Network Overview 6 2 2 MELSECNET H Remote I O network REDUNDANT SYSTEM NETWORKS MELSEC Le caries 8 Settings of Operation Mode for error occurrence For the Redundant CPU and MELSECNET H remote I O station the operation mode z for error occurrence such as fuse blown and I O module comparison error can be a gt i i O set in the PLC RAS settings of the PLC parameter dialog box Qn H Parameter MNET 10H Remote I O station parameter Boot file SFC 1 0 assignment Csystem PUC perational settings 1 0 assignment PLCname PLCsystem PLC file PLCRAS I PLCRAS 2 Device Program WDT Watchdog timer setting Eror check WDT Watchdog timer setting Error check 2 eitir 200 7 n V Cary out battery check aliin na ma ia x sh
301. el Ex 3 eveloper TES j Nz SoZ Arza OES ofa roe Control Standby STOP gt Reset STOP Ol system Remote operation Connection target information Connection interface COM1 lt gt PLC module Target PLC Station no Host PLC type Q25PRH PLC status RUN COT ICO T Cou DCO a Col 600s COUT Ol Tracking cable System type Control system Operation mode Backup mode W 2 gt no E Zz lt x a Zz Q W a 7 2 O QO 2 u Operation Specify execution destination PLC sTOP zi Currently specified station Allstations Extract memory card GX Developer REDUNDANT SYSTEM NETWORKS Diagram 5 101 Remote Reset Operation in Separate Mode PROGRAMMING CAUTIONS TROUBLESHOOTING 5 10 Redundant CPU Functions Restricted in Redundant System 5 137 5 10 2 Remote Operation for Redundant System D REDUNDANT SYSTEM FUNCTIONS MELSEC TE ories c Precautions when executing remote reset operation The following describes the precautions to be taken when performing remote reset for both systems in the backup mode 1 Remote reset when control system CPU mod
302. els 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 tracking cable to the CPU modules and power the systems on again E POINT When starting up a single basic system use the debug mode Refer to Section 5 1 3 for the debug mode System A and System B can be identified by checking whether the special relays System A discriminating flag SM1511 and System B discriminating flag SM1512 are ON or OFF Table5 2 Confirming SM1511 and SM1512 to Identify System A and System B SM1511 SM1512 System A ON OFF System B OFF ON 5 4 5 1 Basic Concept of Redundant System 5 1 1 Determination of System A System B D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 5 1 2 Determination of Control System and Standby System In a redundant system either system CPU module runs the programs controls the system a and communicates with the network w The system that includes the CPU module running the programs is referred to as the 2 Control system The other system serves as a backup for continuing the system operation in the case the module on the control system fails or develops an error 6 This backup system is referred to as the standby system E The standby system CPU module does not run the programs The same status as the Ba 26 STOP status ao The control system and standby system
303. em Confirm the Power Supply Module s POWER LED Confirm that the power supply module POWER LED is lit green and that power is being supplied properly Start standby system Diagram 8 20 Power Supply Module Replacement Procedure POINT When the standby system is powered OFF the control system CPU module develops in a STANDBY SYS DOWN error code 6300 continuation error After the replacement of the standby system CPU module is complete reset errors in the control system CPU module as necessary Refer to Section 8 2 for the error resetting method 8 3 Replacing Module in Redundant System 8 3 2 Power Supply Module Replacement Procedure 8 TROUBLESHOOTING MELSEC LA series 8 3 3 Redundant Power Supply Replacement Procedure When a pair of redundant power supply modules is used in each system one redundant a power supply module can be replaced at a time after powering off the module while the i redundant system is running This operation can be performed in both systems O System control can be continued while the power supply module is being replaced because another power
304. em Do not jump l l D I I 3 j j I i System switching Ea Kans Diagram 7 3 ON OFF Operation of SCJ Instruction When Signal Flow Has Been Tracked 26 25 Pema Z o mod O e cet EO TROUBLESHOOTING 7 1 Instructions Restricted in Use for Redundant System 7 5 PROGRAMMING CAUTIONS MELSEC TE ories 5 Instructions that Change CPU Status When the instruction listed in Table7 3 is executed and the control system CPU module status changes the information of the changed status will not be sent to the standby system CPU module Therefore if system switching occurs it is necessary to use the user program to execute that instruction in the new control system CPU as necessary Table7 3 Instructions that Change CPU Status Instruction Classification Instruction Symbol f Disable Interrupt DI Program Execution Sd Enable Interrupt El ntr dues Interrupt Disable Enable Setting IMASK File Register Block No Change RSET Change Instruction File Register File Set QDRSET Comment File Set QCDSET Application i Timing Clock DUTY Instruction 6 Restrictions when Using Special Relay SM1518 Standby System to Control System Switching Status Flag This section explains how the rise instruction for which SM1518 has been set as its execution condition is processed after system switching on the assumption that signal flow memory has not been tracked a Processing Whe
305. em OR Set the RESET L CLR switch of the standby system CPU module to the central position reset switch neutral position Confirm the Power Supply Module s POWER LED Confirm that the power supply module POWER LED is lit green and that power is being supplied properly Start standby system Diagram 8 32 Tracking Cable Replacement POINT Make sure to replace the tracking cable after powering off the standby system or setting the RESET L CLR switch to the RESET position reset If the tracking cable is connected or disconnected while both systems are running it may result in either of the followings e The scan time is extended and the WDT ERROR ERROR CODE 5000 5001 occurs The TRK CIR ERROR ERROR CODE 1112 1113 1116 occurs and the redundant CPU operation stops 8 46 8 3 Replacing Module in Redundant System 8 3 9 Tracking Cable Replacement 8 TROUBLESHOOTING MELSEC LA cries 8 3 10 Replacement Procedures of Extension Cable 1 Replacement of extension cable An extension cable which connects the main base unit and the redundant type extension base unit of the control system cannot be replaced during operation of the redundant system Before replacing the extension cable always switch the control system to the standby system by GX Developer OVERVIEW 2 Replacement procedures The replacement procedure of the extension cable is shown in Diagram 8 33 CONFIGURATION
306. em CPU module Standby system CPU module Q12PRHCPU Q12PRHCPU MODE RUN MODE RUN ERR I lt USER BAT BOOT ERR E USER BAT BOOT Flashing red Diagram 5 86 LED Indications at Memory Copy Completion 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 Control system CPU module Standby system CPU module ON green Q12PRHCPU Q12PRHCPU MODE BACKUP MODE BACKUP RUN CONTROL RUN CONTROL ERR E SYSTEMA ERR SYSTEMA USER CI SYSTEMB ON green USER SYSTEM B BAT BAT BOOT BOOT ON red OFF Diagram 5 87 LED Indications during Standby System CPU Module Operation 5 120 5 7 Memory Copy From Control System To Standby System D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series
307. em are mounted to MELSECNET H remote 1 O station lt lt First 5 digits of serial No is 09012 or later gt gt Applicable Extension base unit Up to 7 stages e The following modules cannot be mounted Interrupt module MELSECNET H network module Ethernet interface module function version B or earlier e High speed logging is not applicable when the Web server module is used e High speed collection is not applicable when the MES interface module is used e Interrupt pointer and dedicated instruction are not applicable when the intelligent function module is used Restrictions for Mounting Modules on Remote I O Applicable Extension base units Stations e FROM TO instructions and intelligent function System System Extension via Configuration Extension Base Unit Maximum 7 stages module devices U _ GL_ are inapplicable Intelligent function modules use REMFR REMTO instructions for buffer memory access Set the remote I O station intelligent function module using GX Configurator The following modules cannot be mounted to remote I O station MELSECNET H network module interrupt module Web server module e Ethernet interface modules cannot make a communication using dedicated instructions interrupt pointers e mail functions or fixed buffer and do not support FTP server functions or web server functions Intelligent function modules other than above do not support dedicated instructions or i
308. em was powered off e The CPU module in either system was reset and then its RESET switch was set to the neutral position 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 2 The System A CPU module starts as a control system and the System B CPU module as a standby system b Set the RESET switches of System A and System B CPU modules to the neutral position simultaneously 1 Reset the System A and System B CPU modules and then set their RESET switches to the neutral position simultaneously 2 The System A CPU module starts as a control system and the System B CPU module as a standby system 8 1 Troubleshooting Flow 8 1 8 When CONTROL SYS DOWN error code 6310 to 6312 Occurred at Redundant System Startup 8 TROUBLESHOOTING MELSEG LAY series 8 1 9 When ETX CABLE ERR Occurs The following shows the flowchart for when EXT CABLE ERR occurs during operation of a oc the redundant system 3 Error message EXT CABLE ERR was detected rA fe T jag z Are main base unit of control Turn OFF power ioi conirolisystem ng system and Q65WRB connected 4 PONET SERR aT EOLO SY i QS by extension cable no Connect OUT connector of mai
309. en SM1710 is ON When SM1710 is on if a system switching occurs old data will not be output a because tracking is performed also during online program change 2 5 Refer to Section 5 5 4 for tracking data settings z System A CPU module System B CPU module Y100 Control system Standby system external output OFF aa MO MO Circuit before gt program change in C100 C100 5 ladder mode during Ee RUN oc 0 2 i Refresh to the network 9 module nO MO vo r Circuit is added to Y100 I 100 System A CPU 7 module l ha w l When M0 is set to l 2 ON Y100 is also set to ON MO N MO S E 4100 1004 x Set Y100 external fg output to ON Refresh to the network Due to tracking module a MO Y100 will be N amp set to ON MO MO ON Oa 2 ywo iyo H Te cr Zz 204 H REE Sza ceo ane 5 Control system Standby System GStandby system Control System System B CPU a module s Y100 Refresh to the network D external output will be module gt left ON because Y100 i a is ON MO MO Z Z Y1 Y1 Circuit is added to E AE 100 5 5 System B CPU i A E mS module H 4 J H co Refresh to the network module a D MO MO 3 ii Y100 4100 Eo Ze H zO 35 OF oe i T2 Diagram 5 65 Operation When System Switching Occurs during Online Program Change 0 Z o Z g E mO oO Z E Q Q T ol m a gt O iv H 5 6 Writing To The Both Systems Using G
310. ension base unit is connected The module can be replaced without stopping the system when it fails Control system Standby system Failed module Aa Tracking cable MELSECNET H Remote I O network _ Remote I O station Remote I O station j 2 Online module change il Je hot swapping 1 Set online module change hot swapping 3 Cancel online module change hot swapping eae g Replacement module 1 to 3 shows the online module GX Developer change hot swapping procedure Diagram 1 10 Online Module Change Hot Swapping of Remote I O Stations 1 2 Features OVERVIEW MELSEC TAY series OVERVIEW Standby
311. ept watchdog timer error 7 8 TRACKING CABLE Operations on the 2 systems are different detected only in Backup Mode Copying memory from control system to standby system 9 Writing during RUN 10 Detecting network fault on standby system Initializes at 0 at same system power ON Stores 0 when system switching completes successfully REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol The following bits are turned ON for each same system module from which a system switching request was issued e Turns OFF on system after user has removed the corresponding module malfunction Each Bit Bits Same System b15to b11 to b1 bO 0 OFF SD1590 0 0 1 eA 0 1 0 1 0N Network Module 2 SD1590 No Issuing Module 0 Disabled because CPU O O Syst Switchi module is a 2 slot unit yslem witening Module 1 Module to the right of Request CPU module wW i gt no E zZ lt z a W a 7 2 O O Z 5 u Module 11 In 12 Slot Base Q312B the module farthest to the right See SD1690 for the other system module No issuing a system switching request REDUNDANT SYSTEM NETWORKS OSet Not set PROGRAMMING CAUTIONS TROUBLESHOOTING 5 3 The System Switching Function 5 53 5 3 5 Special Relays Registers For System Switching D REDUNDANT SYSTEM FUNCTIONS Mi aL 26 fel ceries Table5 39 Special Registers For System Switching
312. er supply module Generic term for Q series power supply modules AnS series power supply modules slim type power supply module and redundant power supply module Generic term for Q6BAT Q7BAT and Q8BAT CPU module batteries Q2MEM BAT Power supply module Rantary SRAM card battery SRAM card Abbreviation for Q2MEM 1MBS and Q2MEM 2MBS type SRAM card Flash card Generic term for Q2MEM 2MBF and Q2MEM 4MBF type Flash card ATA card Generic term for Q2MEM 8MBA Q2MEM 16MBA and Q2MEM 32MBA type ATA card Memory card Generic term for SRAM card Flash card and ATA card RELEVANT TERMS Relevant Terms Description System A The system to which the system A connector of tracking cable is connected System B The system to which the system B connector of tracking cable is connected Host system The system where the currently mentioned Redundant CPU module is mounted The system connected to the host system via the tracking cable Other system If system A is the host system system B is the other system if system B is the host system system A is the other system The basic system that is controlling the redundant system and performing network Control system oo communication Standby system The basic system for backup that consists of the redundant system The system that has switched to control system from standby system after system New control system aes switching The system that has switched to standby system from control system after
313. ered 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 can be simultaneously cleared Example If errors that correspond to error codes 2100 and 2101 occur both of them will be simultaneously cleared when either one is cleared In the case of errors that correspond to error codes 2100 and 2111 both of them will not be simultaneously cleared even when either one is cleared 2 If an error is caused by other than the CPU module relevant problem its cause will not be removed even when the error clear is performed using SM50 and SD50 Example The cause of the SP UNIT DOWN error cannot be removed by performing error clear using SM50 and SD50 as the error occurs in a base unit including extension cables intelligent function module etc Remove the cause of the error by referring to the error code list 3 If the cause of the error is not removed after error clear has been performed the same error will be detected 8 2 Error Clear 8 27 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS o zZ E eo 0 T o w m 5 O faa E 8 TROUBLESHOOTING MELS
314. eries APPENDICES MELSEC TA eerie The program example of registering the user registration frame No 3E8H is shown in Diagram App 27 For the I O signal is X Y80 to X Y9F PROCESSING TIME FOR REDUNDANT SYSTEMS X50 o PLS M50 Requests registration M50 E J 3 MOV K1 DO J Sets registration request g 2 fi MOV _H3E8 D1 J Sets frame No to be registered a lt F MOV K10 D3 J Sets the number of data byte T to be registered MOV H3946 D4 MOV H3030 D5 x a zZ r J Sets registered data of a frame MOV meee Be 4 to be registered to D4 to D8 MOV H4646 D7 MOV H3030 D8 TO H8 H2000 K1 K1 Ff Sets the write permission to the flash ROM TO H8 H2 DO K2 Registers user registration frame TO H8 H5 D3 K6 SET M1 J Sets the flash ROM write request flag M1 X98 E d 36 E SET Y98 J Writes data to the flash ROM X98 Reads registration result when FROM H8 H4 D2 K1 write completion is turned ON Executes error processing when D2 is other than 0 RST Y98 Resets the flash ROM write request flag RST M1 Diagram App 27 Program Example Appendix 6 Precautions for Using Serial Communication Module App 39 APPENDICES Appendix 6 5 GETE Instruction The following shows the device and buffer memory used in the sample program of reading the user registration frame 1 Device of PLC CPU Table App
315. es The start mode is the mode that determines device status at system startup or unreset RESET L CLR switch is set to the neutral position Two types of start modes are available Initial start mode and Hot start mode Initial start mode is set by default Select the start mode at backup mode settings in the redundant parameter settings of GX Developer Redundant parameter Operation settings Tracking settings Start mode setting Mode Initial start mode Select Initial start mode Hot start mode X It will become Hot start mode during system switching Standby system watch setting IV Check the error in Standby system Debug mode setting C Start with Debug mode Backup mode setting IV Check operating status consistency Diagram 5 17 Operation setting Screen 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 Control using Initial start mode Control using Initial start mode System A Control System System B fc Standby System Col l60 Ls Cole NCSla eST 06 Ola System A Control System
316. es Signal flow memory tracking setting No tracking i F All tracking device capacity 01 K word c Enable tracking of signal flow memory Device total increases 16K word Device detail settings Tracking block No 1 X Vv ee block No 1 r Device inge settings Devise Pone sen En I Points Start Start End 1113 Device total 77 Maximum 100K Kword File register file settings Target memory File name 1 2 3 4 5 6 if 8 3 0 Tracking characteristics setting Synchronized tracking mode T ake more scan time Program priority mode Diagram App 3 Tracking Setting Screen The remote output Y1000 toY109F and remote register W1100 to W1113 will be tracked with the default setting Internal Device Batch Setting in the tracking device settings too Appendix 4 Sample Programs when Using CC Link App 15 MELSE TE ories PROCESSING TIME FOR REDUNDANT SYSTEMS APPENDICES INDEX APPENDICES a M 3 CC Link Network Parameter Settings a Example of CC Link Network Parameter Settings ELSECTA eries An example of CC Link network parameter settings is shown in Diagram App 4 Refer to b for the actual settings W Network parameters Setting the CC Link list of boards in module 1 _y Boards Blank no setting Start 1 0 No Po Operational setting Operational settings a Type Master station Duplex function
317. es starting at the connection terminals For wiring a terminal block be sure to use a solderless terminal To prevent short circuit due to loosening screws use the solderless terminals with insulation sleeves of 0 8 mm 0 03 inch or less Also only two solderless terminals can be connected per terminal block Terminal block Solderless terminals with insulation sleeves 2 Supply power to two redundant power supply modules individually redundant power supply 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 the input voltage touching this terminal may result in an electric shock 5 When using the redundant power main base unit ON short circuit timing of ERR terminal on the redundant power main base unit is delayed than that of ERR terminal on the redundant power extension base unit by the CPU module initial processing time 4 2 Wiring PROCEDURE FOR STARTING UP A REDUNDANT SAE MELSEC Kel ceries 2 Connecting the Q6BAT Battery Connectors The CPU module Q6BAT batteries are shipped with the battery connectors z disconnected z Connect the battery connectors according to
318. eseeceecscecccoccocooccoccecosecoccocsocosscoeceeoseeoe G 45 Communication when the GOT is Connected to MELSECNET H or MELSEGNET 10 PLC to PLC Network ecccccccccccccccccccccccccccccccccccccsccccccsccscocsocscocsoeses G AG When Connecting GOTS to a Ethernete eeeeeeseecseeeccoecoecccccocccecoccoccococccoccoccoecocosccooooe G 47 6 4 Precautions for Accessing Redundant CPU from Other Networks eeeeeeeeesceeeecccoeeooccoocoosoo000 G 49 6 5 Precautions for Writing Device Data from Other Station seeeeeeseeeesesesecoesocecoccecocoesececoesecoeo G 5 CHAPTER7 PROGRAMMING CAUTIONS 7 1to 7 22 7 1 Instructions Restricted in Use for Redundant System cooooooooooooooooooooooooooooooo00000000000000000000000 1 7 2 Cautions on Fixed scan Clocks Programs coooooooooocoooooo0o0000000000000000000000000000000000000000000000000 9 7 3 Precautions for Using Annunciator F in Redundant Systemeeeeeceeccececcecccceccccscccccccccescccecee 7 14 7 4 Precautions at System Switching Occurrence cocoococooocoocooooooooo00000000000000000000000000000000000000 16 7 5 Precautions of Programming when Connecting Extension Base Unit seeeeeeseeesseeeseeccoocesoccoosoo 7 22 CHAPTER8 TROUBLESHOOTING 8 1to8 48 8 1 Troubleshooting Flow ccocoooooooooooooooo00000000000000000000000000000000000000000000000000000000000000000000000000 3 8 1 1 8 1 2 8 1 3 8 1 4 8 1 5 8 1 6 8 1 7 8 1 8 8 1 9 8 1 10 8 1 11 8 1 12 Flow for the Case where the
319. esenative reseller or branch office and explain the fault symptoms For the control system network module are there any faulty modules SD1690 0 Confirm the status of the standby system network module modules compatible with SD1690 bit set to ON and correct any problems Using GX Developer or a switching instruction reissue a system switching request and check that the system switches Did the switch occur normally Check again following the flow for Completed systems did not switch If the systems do not switch for the same reason even after performing the above checks please contact the nearest Mitsubishi represenative reseller or branch office and explain the fault symptoms Diagram 8 9 Flow in the Case of System Switching due to Control System Error or System Switching Instruction Execution 8 1 Troubleshooting Flow 8 1 6 When System Switching has failed 8 TROUBLESHOOTING MELSEG LAY series 8 1 7 When TRK INIT ERROR error code 6140 Occurred at Redundant System Startup 1 TRK INIT ERROR occurrence conditions TRK INIT ERROR occurs when either of the following operations is performed until the BACKUP LED is lit green during a startup of the redundant system e Either system was powered off e The CPU module in either system was reset OVERVIEW 2 Corrective action for TRK INIT ERROR If TRK INIT ERROR has occurred during a startup of the red
320. etting time for redundant Tre1 Signal Flow Memory 2 1 0 13x 10 xZ parameter tracking settings Tre2 SFC Information SFC program execution time 1 Fixed PIDINIT instruction execution fa i 0 5 Fixed 2 ime Dreg PID Control Instructions S PIDINIT instruction er 0 5 Fixed execution time Tre4 Device Data X1 X2 X3 Z Number of Program Steps X1 to X3 are calculated as follows X1 Processing time according to number of device points for tracking settings X1 D1 x K1 D2 x K2 D3 x K3 D4 x K4 ms X2 Processing time according to number of device ranges for tracking settings X2 E1 x K5 E2 x K6 E3 x K7 E4 x K8 ms X3 Processing time according to number of tracking blocks for tracking settings X3 F1 x K9 F2 x K10 F3 x K11 ms D1 to D4 E1 to E4 F1 to F3 and K1 to K11 are values used in Table9 6 9 2 System Switching Time 9 7 Q PROCESSING TIME FOR REDUNDANT SYSTEMS Mi aL EC Kel ceries Table9 6 Counting Value of D1 to D4 E1 to E4 F1 to F3 and K1 toK11 Saat Countin unti Content Number e Value Symbol D1 Number of Tracking Device Points outside of Index Register K1 0 09x 103 D2 Number of Tracking Device Points for Index Register K2 0 15 x 10 Number of Tracking Device Points for Standard RAM File D3 K3 0 09x10 Register Number of Tracking Device Points for SRAM Card File D4 l K4 0 42x10 8 Regis
321. etwork module x ae System System power OFF O Switching CPU module reset O CPU module hardware malfunction O Manual System swiching instruction x g cout Syst ichi tf GX Devel 2 eats stem swiching request from eveloper lt Switching y g req P x Yes xNo 1 The CAN T SWITCH error code 6220 continuation error occurs in control system CPU module n A that executed the system switching instruction 2 lt Ea System switching has failed due to online program change is set in the detailed information zok special relay a Z a 2 The error dialog box in Diagram 5 67 will appear on the GX Developer which requested the Se a system switching L Ol E MELSOFT application j This peripheral device or another peripheral device are operating online change Function AB Please execute it again after it completed online change Function lt ES 010a424c gt Diagram 5 67 Error Dialog Box Displayed on GX Developer wW wn gt 2 Zz lt j zZ W ve 7 2 Q oO 2 u 5 Waiting Time Check for Online Program Change to Standby System The waiting time check for online program change to the standby system abnormally completes the online program change and enables the online program change again E 2 when a communication error occurs between GX Developer and the control system Em standby system CPU module ge When the time from when the online program change to the control
322. eveloper Version 8 18U or later is applicable Version 4 or later is applicable Program App 6 Instruction restriction Instructions shown in Table App 5 is inapplicable Floating point calculations Only internal operation processing with single precision Internal operation processing precision level single double is not selectable Internal operation processing precision level single double is selectable High speed interrupt 149 N A Applicable Slow speed execution type program 2 N A Applicable MELSECNET H network system remote I O stations have a limit for the maximum number of parameters that can be set with GX Configurator as intelligent function modules The maximum number of parameter settings for initialization settings 512 The maximum number of parameter settings for automatic refresh settings 256 Appendix 2 Comparison of Qn H CPU and QnPRHCPU APPENDICES MELSEC LE series w Table App 4 Instructions Inapplicable for QNPRHCPU Z Z oa Instructi Instruction Zz ASE Instruction Name Instruction Name BB 2 symbol symbol Wa i PLOADP Program Load from Memory Card PLSY Pulse Output gS PUNLOADP Program Unload from Memory Card PWM Pulse Width Modulation PSWAP Load Unload MTR Matrix input PR Print ASCII code S TO Write To Host Station CPU Shared Memory PRC Print Comments S P SFCF Request of Motion SFC P
323. evice data Specify the control system and read the following special relays System A identification flag SM1511 System B identification flag SM1512 NO Communication failure System switching occurred Can the data be read normally YES Communication normal Change the connection setup Are the SM1511 and SM1512 contents read in 1 and 3 consistent NO Inconsistent System switching occurred YES Consistent End Diagram 6 42 Flowchart for Checking for System Switching with the system A and system B identification Flags 6 52 6 5 Precautions for Writing Device Data from Other Station PROGRAMMING CAUTIONS Mi aL 2G LAY series m This chapter provides the programming cautions restrictions on instructions fixed scan a clocks programs 7 1 Instructions Restricted in Use for Redundant System Some instructions are restricted in use to a redundant system as indicated below 7 o Pa PE 1 Instructions Requiring a Certain Number of Scans 25 a Instruction Operations Some instructions require a certain number of scans from start to completion of the execution If system switching conditions are satisfied while this kind of Hw instruction is being executed the CPU stops the execution and the relevant 5 Oo processings will not be completed g 2 ies s Q In this case it is necessary to use the user progr
324. f System Switching by GX Developer 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 Did the switch occur normally Check again following the Completed troubleshooting flow for systems did not switch If the systems do not switch for the same reason even after performing the above checks please contact the nearest Mitsubishi represenative reseller or branch office and explain the fault symptoms Diagram 8 8 Flow for the Case where System Switching Has Failed 8 14 8 1 Troubleshooting Flow 8 1 6 When System Switching has failed 8 TROUBLESHOOTING MELSEG LAY series 2 In the Case of System Switching due to Control System Error or System Switching Instruction Execution A oc Systems did not switch z rA Is the BACKUP LED lit NO Debug mode e ae Green Red Backup Mode Turn off debug mode redundancy 26 Amber Separate Mode parameters and change to backup mode i i P NO Is the SYSTEM A B LED lit 3 Oo Z YES Reconfirm the connection status of the 5 tracking cable for both a systems Reconnect E lt System A For system A if a cable has been disconnected during normal operation the LED will flash until A system s connector is reconnected T u System B For system B if a cable has Q lt 2 b
325. f the communication is interrupted between the redundant CPU module and 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 this case enable the system switching by performing the following operation in order to enable the manual system switching or system switching by network module system switching request e Turn on the control system CPU module special relay Disable prohibition of system switching during Online program change SM1709 e Perform online program change again to complete it 5 3 The System Switching Function 5 3 6 System Switching Precautions D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 5 4 Operation Mode Change Function 2 types of redundant system operation mode change are available Change from the backup mode to separate mode z e Change from the separate mode to backup mode Refer to Section 5 1 3 for details on the backup mode and separate mode z jag o bs as S fe ai woe aga OES Ol wW no gt 2 E zZ lt z Q W a 7 2 Q oO 2 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLES
326. fer to Section 4 1 Refer to Section 4 2 Refer to Section 4 3 Refer to Section 4 4 Refer to Section 4 5 Refer to Section 4 6 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE A W n gt n 2 A lt a Zz a W oc aj X lt aS oi ze aw REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 4 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM M eLSEC Aries l Writing Parameters and Programs to CPU Write the parameters and programs created with GX Developer to the CPU modules of System A and System B Restarting System A and System B 1 Power off system A and system B or toggle RESET L CLR switch of CPU module 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 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 of GX Developer and eliminate it Check the control system standby system by the CONTROL LED status of each CPU module Running Standby System System B CPU Module 1 Set the RUN STOP switch of standby system CPU module the CONTROL LED is OFF to the RUN position and confirm that the RUN LED of CPU m
327. ficult to determine if its execution is lt fE completed or not However note that the same instruction might be executed twice i con Pa woe ToT Lu bE n 29 56 Zr 2 S Ei wW D cw wW H n a2 oc ma Be W W az Z o eo g cet EO TROUBLESHOOTING 7 1 Instructions Restricted in Use for Redundant System 7 3 PROGRAMMING CAUTIONS 2 3 MELSEC TA ories Rise Instruction If signal flow memory has not been tracked after system switching the rise instruction is processed as explained below a Processing When system switching occurs the new control system CPU module turns on signal flow memory in all steps Therefore the CPU module does not execute the rise instruction even when the rise instruction execution condition is satisfied during system switching b Relevant Instructions LDP ANDP ORP e MEP PLS OP Examples MOVP INCP etc e SP GP 9 ZP g JP g Intelligent Function Module Dedicated Instructions Fall Instruction If signal flow memory has not been tracked after system switching the fall instruction is processed as explained below a Processing When system switching occurs the new control system CPU module turn signal flow memory in all steps Therefore the CPU module executes the rise instruction again if the fall instruction execution condition has turned OFF before system switching execut
328. g cable Z Q 25 Diagram 5 8 System Switching Operation in Backup Mode Ta 0 zZ o 56 22 O 0 zZ E Q fe ae N a oc 5 1 Basic Concept of Redundant System 5 9 5 1 3 Operation Mode D REDUNDANT SYSTEM FUNCTIONS 5 10 MELSEG TA ories a Confirming Backup Mode Confirm that the redundant system is running in the backup mode by checking the BACKUP LEDs of CPU modules Table5 5 Checking the BACKUP LED to Confirm the Backup Mode CPU Module LED LED status Q12PRHCPU Control Standby MODE LED Name MUN System System pat BACKUP ON green ON green BOOT Refer to the following manual for details on the CPU module LED lt gt QCPU User s Manual Hardware Design Maintenance and Inspection b Precautions 1 When the system A and system B CPU modules are reset simultaneously RESET L CLR switch is set to the RESET position or unreset RESET L CLR switch 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 backup mode X In the backup mod
329. g conditions a When the Operation Mode is Backup Mode 1 When System Switching Occurs before Execution of the Interrupt Program The control system CPU module holds the received interrupt factor even when it becomes the standby system CPU module through system switching before the interrupted program is executed When switching is done again and the standby system CPU module returns to the control system CPU module it executes the interrupt program for the held interrupt factor Since the interrupt factor accepted by the control system CPU module is not taken over by the new control system CPU module the new 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 executes the interrupt program for the held interrupt factor POINT The interrupt program corresponding to the held interrupt factor is executed when the standby system CPU module becomes the control system CPU module through system switching If multiple interrupt factors are held in the standby system CPU module the scan time is widely extended b When the Operation Mode is Separate Mode Both control system CPU module
330. ged 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 OFF registration cannot be executed individually for the control system and standby system CPU modules 5 10 Redundant CPU Functions Restricted in Redundant System 5 10 1 Enforced ON OFF of external I O 5 130 D REDUNDANT SYSTEM FUNCTIONS Mi aL 3G Kel ceries 4 Operation When Control System Standby System Is Powered Off and Then On CPU Module Is Reset and Then its RESET Switch Is Set to Neutral Position OVERVIEW a In the backup mode 1 Operation when control system is powered off and then on control system CPU module is reset and then its RESET switch is set to neutral position System switching occurs when the control system is powered off the control system CPU module is reset The input output of which forced ON OFF has been registered remains the ON OFF status according to the forced ON OFF information of the new control system CPU module CONFIGURATION SYSTEM Table5 61 Operation When Control System Is Powered Off and Then On Control System CPU Module Is Reset and Then its RESET Switch Is Set to Neutral Position Module mounted on main base unit including Redundant CPU Module mo
331. generated JJ while executing Online Function to the control system PLC lt E5 010a4253 gt Diagram 5 73 Error Dialog Box Displayed on GX Developer CONFIGURATION SYSTEM 4 Online program change to CPU module during system switching or operation mode change The error dialog box in Diagram 5 74 will appear if online program change is executed during memory copy from the control system to the standby system E MELSOFT application O The specified file does not exist J Please execute again after confirming the file TRACKING CABLE lt E5 010a41c5 gt Diagram 5 74 Error Dialog Box Displayed on GX Developer In the separate mode online program change is executed only to the system that specified in the target connection settings Online program change is not executed to the CPU module of the system that is not specified in the target connection settings REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol Extension of scan time due to online program change If online 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 Lu no gt no E Zz lt q Z Q W a 9 2 O QO 2 u L7 QCPU User s Manual Function Explanation Program Fundamentals Signal Flow Processing 7 The signal flow in the changed steps or program turns on Em Therefore if a running prog
332. ger SM1551 Tracking Block No 32 Tracking Trigger SM1552 Tracking Block No 33 Tracking Trigger SM1553 SM1554 Tracking Block No Tracking Block No 34 Tracking Trigger 35 Tracking Trigger SM1555 Tracking Block No 36 Tracking Trigger SM1556 Tracking Block No 37 Tracking Trigger SM1557 Tracking Block No 38 Tracking Trigger SM1558 Tracking Block No 39 Tracking Trigger SM1559 Tracking Block No 40 Tracking Trigger SM1560 SM1561 Tracking Block No Tracking Block No 41 Tracking Trigger 42 Tracking Trigger SM1562 Tracking Block No 43 Tracking Trigger SM1563 SM1564 Tracking Block No Tracking Block No 44 Tracking Trigger 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 49 Tracking Trigger SM1569 Tracking Block No 50 Tracking Trigger SM1570 Tracking Block No 51 Tracking Trigger SM1571 Tracking Block No 52 Tracking Trigger SM1572 Tracking Block No 53 Tracking Trigger SM1573 Tracking Block No 54 Tracking Trigger SM1574 Tracking Block No 55 Tracking Trigger SM1575 Tracking Block No 56 Tracking Trigger SM1576 Tracking Block No 57 Tracking Trigger SM1577
333. he control system CPU module receives the system switching request from that Ethernet interface module The system switching request can be set to be issued or not in the network parameters as indicated in 3 Communications error occured System A Control System a System B Standby System fel f fel g ooo000 al System switching request c O O System A Control System System B Standby System A g E nooo oo0000 Communication not possible malfunction severed cable i odimumantyfo Colle l6 oar col Ne o Diagram 6 21 Operation when a communication error or disconnection is detected 1 Indicates the FA communication middleware for programmable logic 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 software using FA devices made by Mitsubishi Electric which operate on Windows personal computers 2 Only the QJ71E71 100 can detect disconnection A system switching request is not issued when Ethernet i
334. hen memory copy begins the MEM COPY EXE error code 6410 continuation error will occur in the control system CPU module and then the STANDBY SYS DOWN error code 6300 continuation error will occur e 4 When memory copy begins the PRG MEM CLEAR error code 6400 stop error will occur in the standby system CPU module 22 RO GE E O o zZ E Q fe ae N W a oc E 5 7 Memory Copy From Control System To Standby System 5 117 D REDUNDANT SYSTEM FUNCTIONS 5 4118 MELSEC TE ories 5 When memory copy is complete the BACKUP LED of the standby system CPU module will turn on red Control system CPU module Standby system CPU module Q12PRHCPU Q12PRHCPU MODE RUN ERR USER BAT BOOT MODE RUN ERR E USER BAT BOOT Flashing red Diagram 5 81 LED Indications at Memory Copy Completion 6 When memory copy is complete 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
335. hen memory copy is abnormally completed SD1596 other than 0 error code Ol wW no gt no E zZ lt q z Q W a 2 Zz O O Z u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 7 Memory Copy From Control System To Standby System 5 115 5 REDUNDANT SYSTEM FUNCTIONS 2 Confirmation by GX Developer Whether memory copy is normally completed or abnormally completed can be checked on the Redundant operation screen of GX Developer MELSEC TE eries Redundant operation Connection target information Connection interface COM1 fo Station no Host Target PLC PLC status RUN System type Control system Operation mode lt gt PLC module PLC type Q25PRH Backup mode Redundant operation Connection target information Connection interface COM1 lt gt PLC module Target PLC Station no Host PLC status RUN System type Control system Operation mode PLC type Q25PRH Backup mode Remote operation System switching Memory copy progress status Remote operation System switching Memory copy progress status Memory copy failure Change operation mode ha ion co Diagram 5 75 Redundant Operation Screen Showing Change operation mode Zi Diagram 5 76 Redundant Operation Screen Showing Normal Completion Abnormal Completion 2 Memory Copy from Control System to Standby Sys
336. hether the accessible remote I O stations for the master station and sub master station are identical is called the network separation check The UNIT LAY DIFF occurs in the MELSECNET H multiplexed remote I O network that uses optical cables when a disconnection occurs simultaneously at the following locations e Between the master station and sub master station e 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 UNIT LAY DIFF Multiplexed Remote When Point A and any of Multiplexed Remote Master Station Point B D are simultaneously Sub master Station station No 0 disconnected station No 1 Standby _ Control system N system h Sica ee len a IL ooo000 nooo a Gaa f cliem a cole fm Cale earicaka Tracking cable Point D Point A Point B MELSECNET H Remote I O network Point C H g EY Wd 3 EF
337. ics Correct the fault 1 a be O no Monitor the SD1690 with GX Developer and check the network module that requested the system switching Correct the network fault m z O Oo zZ xe Q Monitor the system switching cause using E Is switch factor 16 GX Developer PLC diagnostic error information and check for system switching instruction arguments Correct abnormal behavior as appropriate for the iu argument T Be uw N woe BER Confirm with the GX Developer E be Be which performed the system switching NO E a ze This is a hardware fault in the CPU a6 module so please contact the nearest 55 Mitsubishi represenative reseller or u5 branch office and explain the fault symptoms Diagram 8 7 Flow for the Case where System Switching Occurred a pi n a ZO Ax ZO SE W W EA 0 Z no 22 O 1 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 o Zz Q O T o wW m O iva E 8 1 Troubleshooting Flow 8 13 8 1 5 When System Switching has Occurred 8 TROUBLESHOOTING M BLS AG A i 8 1 6 When System Switching has failed The following flow Diagram 8 8 is for the case where system switching has failed even though a system switching condition was satisfied while the redundant system was running 1 In the Case o
338. idirectional 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 L7 Q Corresponding MELSEC Communication Protocol Reference Manual POINT When the extension base unit is mounted to the serial communication module create programs using the FROM TO instruction since the dedicated instructions cannot be used For the sample program using the FROM TO instruction refer to Appendix 6 6 34 6 2 Redundant System Network Overview 6 2 5 Serial Communication Modules 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series 1 Communication between External Devices and Control System CPU Module if gt jam a Communication by MC Protocol z 1 When mounting to the extension base unit There are restrictions on the connection destination depending on the command from the external device to MC protocol E Appendix 7 1 2 In addition when system switching occurs the communication timeout will se w occur since both old system and new system cannot respond Therefore GZ no perform retry processing by MC protocol Control system Standby system E O a a E 3 Tracking cable lt E Serial communication Extension cable module
339. igent function module are mounted Other name for Q65WRB extension base unit for redundant system on which redundant Q60 WRB power supply module Q series I O module and intelligent function module are mounted Main base unit Generic term for Q3LIB and Q3LIRB Extension base unit Generic term for Q5 _ B Q6L_ B Q6L_JRB and Q6 RB Slim type main base unit Generic term for Q3L_SB Redundant power main base unit Generic term for Q3L IRB Redundant power extension base Other name for Q6L_IRB unit Redundant type extension base Other name for Q6 WRB unit Generic term for main base unit extension base unit slim type main base unit Base unit redundant power main base unit redundant power extension base unit and redundant type extension base unit A 19 Generic Term Abbreviation Description f Generic term for redundant power main base unit redundant power extension base unit Redundant base unit and redundant type extension base unit Generic term for QC05B QC06B QC12B QC30B QC50B QC100B extension cables Generic term for QC10TR and QC30TR tracking cables for Redundant CPU Generic term for Q61P A1 Q61P A2 Q61P Q62P Q63P and Q64P power supply modules Extension cable Tracking cable Q series power supply module Slim type power supply module Redundant power supply module Generic term for Q61SP slim type power supply module Generic term for Q63RP and Q64RP redundant pow
340. in general industries etc Thus applications in which the public could be affected such as in nuclear power plants and other power plants operated by respective power companies and applications in which a special quality assurance system is required such as for Railway companies or Public service purposes shall be excluded from the programmable logic controller applications In addition applications in which human life or property that could be greatly affected such as in aircraft medical applications incineration and fuel devices manned transportation equipment for recreation and amusement and safety devices shall also be excluded from the programmable logic controller range of applications However in certain cases some applications may be possible providing the user consults their local Mitsubishi representative outlining the special requirements of the project and providing that all parties concerned agree to the special circumstances solely at the users discretion a MITSUBISHI ELECTRIC HEADQUARTERS EUROPEAN REPRESENTATIVES EUROPEAN REPRESENTATIVES EURASIAN REPRESENTATIVES MITSUBISHI ELECTRIC EUROPE B V EUROPE GEVA AUSTRIA Beijer Electronics UAB LITHUANIA Kazpromautomatics Ltd KAZAKHSTAN German Branch Wiener Stra e 89 Savanoriu Pr 187 2 Scladskaya str Gothaer
341. in three seconds of one another system A becomes the control system 2 1 System Configuration 2 SYSTEM CONFIGURATION MELSEG Fl cries b Backup of Power Supply Module The power supply module of each system can be backed up By adding backup power supply modules to system A and system B even if an error occurs in the power supply system connected to one power supply module or if the power supply module fails the other power supply module can continue the operation This enables the faulty power supply system to be restored and the faulty power supply module can be replaced while the system is running The power supply module can also be replaced for preventive maintenance while the system is running N OVERVIEW 2 O z gt o iE Z SYSTEM Make Redundant Power supply module redundant Make Redundant Power supply module redundant System B n Standby System S zZ xe Q x fe ci cn Oar Q38RB u ae aga Tracking cable wes SEa W Q63RP Q64RP Q63RP Q64RP a Two modules mounted on Q38RB Two modules mounted on Q38RB Diagram 2 3 Power Supply Modules and Redundant System z n c Module which can be mounted to main base unit or extension base unit 2 For the module which can be mounted to the main base unit or extension base 2 unit refer to Section 2 3 55 wW D cw d Redundant System Operations Refer to Section 5 1 for redundant system o
342. ion b Relevant Instructions e LDF ANDF ORF MEF PLF 7 1 Instructions Restricted in Use for Redundant System PROGRAMMING CAUTIONS MELSEC TAY series 4 SCJ Instruction Note that jump processing for the specified pointer P varies with whether tracking z signal flow memory has been tracked or not if the SCJ instruction contact turns ON a x x gt during system switching processing 2 a When signal flow memory has not been tracked Jumping is executed from the first scan after system switching rA fe b When signal flow memory has been tracked i i 3 jag Jumping is executed from the second scan or later after system switching o Se nz When Signal flow memory is not tracking ao Begin system switching System Switching complete i i y SCJ Instruction ON l T a Point l l OFF i l g 1 Ze I E l After switching Jump ze od oral Jump i i from the first scan fe system Do not jump i i SCJ jum l l new control Jump l ci system Do not jump j 8 a 5 l System switching l WS 5 Doct aes SeS When Signal flow memory is tracking fe g awn Begin system switching System Switching complete i scan Ss W ON l D SCJ Instruction T i gt Point OFF l l Eo l fl 22 After switching J ZE l er switching Jump 50 od patie Jump from the second scan D 5 system Do not jump l l l l i l I l SCJ jum f i new coritrol Jump i a syst
343. ion Details Outline QCPU User s Manual Function Explanation Program Fundamentals Cele DUR Ce Rio CPU Module User s Manual Hardware QCPU User s Manual Multiple CPU System QnPRHCPU User s Manual Redundant System Outline Confirmation of connection methods for power supply module base unit and I O module rere Construction of redundant system confirmation of start up procedure and I O number assignment halen ee Details Confirmation of the configuration and memory of sequence programs Details Confirmation of the functions parameters devices etc of the CPU module Confirmation of the troubleshooting Details ea ass Details Confirmation of the error codes Details OVERVIEW Table1 8 List of programming manuals of redundant CPU S Common Instructions PID contro Instructions Process control Instruction al Q series 5 Structured Text w S wi gt O QCPU Q mode QCPU Qmode QnPHCPU QCPU Q mode QnACPU QnACPU QnPRHCPU QCPU Q mode QCPU Q mode Proarammin E Programming Programming Programming QnACPU Programming g g E Purpose Manual E Manual Manual PID Manual Process Programming LEUEN Structured Text a Common Control Co
344. ion of the system depending on the failure status In addition o5 A O when system switching occurs due to errors of the extension base unit or the module on the extension base unit Create a safety circuit externally so that the overall system can operate safely even in these cases o P EEEE EEEFEEEEEEEFEEEFEEEEESEFEFEEEEEEESEESEREEEEEEREEEE 5 2 N 5 a oc H 1 1 Redundant System Overview 1 11 1 OVERVIEW MELSEG TA series 1 2 Features Features of redundant system are indicated below 1 Redundant Configuration of Basic System As a redundant system consists two basic systems i e two sets of CPU modules power supply modules main base units network module etc one of the basic systems controls the whole system while the other one performs backup Data of the CPU module performing control is transmitted to the backup CPU module in order to make the data consistent This enables the backup system to take over the redundant system control after the control system goes down and system switching occurs Control system Network module Standby system CPU module Power supply Continue control using device data from control system Tracking cable Diagram 1 2 Redundant Configuration of Basic System 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 syste
345. ion screen of GX Developer When Both systems A amp B is selected GX Developer executes remote 2 E operation in order of the standby system CPU module and control system CPU module fi n cas Control system O 9 O e E By g g o O e O o O 5 o Zz 5 5 Tracking cable lt E W x D GX Developer Rar H55 Remote operation R z Connection target information 3 z 3 Connection interface COM1 lt gt PLC module RUN RUN STOP ane Target PLC E Stationno Host PLC type G25PRH Control system Standby system 5 PLC status RUN g g E a Senne EEE era E 8 B S a 8 al E PLC C Currently specified station 5 B y el lel i rai oe R ait by Extract memory card o lt C Specific group 7 S 2 c Baik yim WEB Tracking cable 50 O i fe Te z E W GX Developer D d A Ax 2O Be Llu W az Control system IF Rl amp O e 3l e SIBE Z o Tracking cable 6 65 ct eC GX Developer g Diagram 5 98 Remote STOP Operation When Both Systems Are Specified Q fe a O oc E 5 10 Redundant CPU Functions Restricted in Redundant System 5 135 5 10 2 Remote Operation for Redundant System D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 3 Remote reset 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 i
346. is detected and the number of annunciators that detected errors can be checked using the special relay and special register below e SM62 Detection of annunciator ON e SD63 Number of annunciators ON Perform error clear operation repeatedly until SM62 will be off or SD63 will be 0 then turn all annunciators from ON to OFF 8 TROUBLESHOOTING MELSEC TE ories 8 3 Replacing Module in Redundant System a 8 3 1 CPU Module Replacement gt 1 CPU Module Replacement The control system CPU module cannot be replaced while redundant systems are running Ee When replacing the control system CPU module use GX Developer to switch its E jag system to the standby system then start the replacement operation o A 2 Control system Standby system E f wW a lt O Oo Tracking cable Z 2 lt gt Replace after using GX Developer to GX Developer switch over to the standby system z A Diagram 8 15 System where Control System CPU Module is Repl
347. is done with the other system system A via the tracking cable ink System A Control System S ystem B bea lt D gt Communicate with the System A s CPU module GX Developer 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 module connected to GX Developer is system B communication is done with that CPU module If the CPU module connected to GX Developer is system A communication is done with the other system system B via the tracking cable System B GX Developer System A Control Sys Tracking ca em System B Standby System z E l Communicate with the System B s CPU module System A Control System S l Aa fi Tracking cable ystem B Stan System a GX Developer Communicate wi h the System B s CPU module 6 1 Communication with GX Developer and PX Developer 6 1 1 Communication Methods with GX Developer 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series 6 1 2 Confirming the Connection Target on GX Developer The current communication target CPU
348. itching Timing Device in which Initial Value is novel CPU Module Device Data CPU Module Device Data Received Tracking Data Device in which Initial Device ce isst Preset Initial Device Data CPU Module Device Data Received Tracking Data ue i 1 If received tracking data is not stored in the specified device the CPU module will begin operation after storing tracking data in the specified device Tracking in Program Synchronized Mode gt Preparation Preparation Preparation fa apiece Waiti Waiti Waiti ee FA aiting END f aiting END y i aiting Initial processing Scan Scan Scan Control AN A ie oa system CPU i 5 5 module Send m Send H Send Transfer Transfer Transfer Receive __ Receive H Receive H i Adjust k Initial processing Adjust Standby m l _ system CPU module 2 Initial execution type program 3 Prepare tracking data Tracking data 4 Scan execution type program Tracking data not received received 5 Tracking processing rn 6 Adjust tracking data Receiving Tracking Data Diagram 5 57 Tracking Operation Timing in Program Synchronized Mode 5 98 5 5 Tracking Function 5 5 8 Device Data Used By The New Control System D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 5 6 Writing To The Both Systems Using GX Developer In the backup mode GX Developer writes the same program to the control system and standby system CPU modules t
349. itching must not be executed 1 h fl M10 System switching execution flag ON system switching executed 3 POA OFF system switching must not be executed 102 Bf hing fl M10 System B first startup system switching flag ON system switching executed OFF normal M202 SP CONTSW instruction error flag ON error OFF Not executed data link Duri link i Mee Urinig Gata link execution ON During data link execution D100 D107 Interrupt enable or interrupt disable IMASK 0 interrupt prohibited instruction 1 interrupt enabled SD1601 System switching condition 16 system switching instruction SD1602 System switching instruction argument Argument specified by SP CONTSW instructions Switches the stand by master station in CC Link to 141 Pointer performed at STANDBY error y om the master station 2 CC Link Master Local Module Devices Device Number Table App 11 CC Link Master Local Module Devices Application Remarks OFF Module normal 4 Modul mas ogule srror ON Module error OFF Data link is stopped X41 Host data link status Ph ON Data linking in progress OFF Operation not possible X4F Modul allie steady ON _ Operation possible er OFF Not requested B4 F hin SB40C orced master switching ON Requested OFF Not instructed B401 Refresh i ion n master switchin SB40 efresh instruction at standby witching ON issttusted p442 Refresh instruction acknowledgment status at OFF Not e
350. itten device data from the control system CPU module to check whether system switching occurred or not REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Start j lt Specify the control system and write device data REDUNDANT SYSTEM FUNCTIONS ez Specify the control system and read the written device data NO Communication failure System switching occurred wW i gt no z lt q Q z Q W a 9 X faa Q z 2 W Zz Can the data be read normally YES Communication normal Change the connection setup 0 Are the read device data is consistent with 292 the written device data NO Inconsistent System switching occurred ee E O YES Match End oO Z Diagram 6 41 Flowchart for Checking for System Switching with the Written Device Data 8 5 W a oc E 6 5 Precautions for Writing Device Data from Other Station 6 51 6 REDUNDANT SYSTEM NETWORKS Mi aL 20 fel ceries b Checking for system switching by system A and system B identification flags Whether system switching occurred or not can be confirmed by checking the system A and system B identification flags before and after write of device data eee 1 Specify the control system and read the following special relays System A identification flag SM1511 System B identification flag SM1512 2 Specify the control system and write d
351. k system including reserved stations to 4 Systems App 16 Appendix 4 Sample Programs when Using CC Link APPENDICES CC Link station information Module 1 pcan susinyge Expanded Exclusive station Remote station Reserve invalid Intelligent buffer select word Station type o B setting count points station select Send Receive merri Remote 1 0 station Exclusive station ly o setting Md Remote 1 0 station 3 ESO y Remote device station MELSEC TA ories 6 Special Relay SB Set the special relay SB refresh device to SB400 Special relay SB 7 Special Register SW Set the special register SB refresh device to SW400 Special register SW 8 Retry Count Use the retry count for communication errors to 3 Default PROCESSING TIME FOR REDUNDANT SYSTEMS 9 Automatic Reconnection Station Number 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 APPENDICES INDEX 13 Delay Information Setting Use the link scan interval as 0 Default 14 Station Information Setting Set the station information to Station Information Settings as shown in Diagram App 5 pede E
352. king connecting Manual switching Enable Monitor run stop Stop monitor PLC diagnostics PLC status PLC operation status PLC operation STOP switch STOP Connective system Standby system System B Backup mode Tracking connecting Manual switching Enable Present Error PLC Module Present Error System A No error System B No error Year Month Day Monitor run stop lt Stop monitor Error Jump Help Error log Error log Clear log No Error message 6210 STANDBY Year Month Das 2002 2 1 d Eror Jump Help Diagram 5 21 New Standby System PLC Health Check Display 1 System switching can be done from the OPS application using EZ Socket too 2 Ifthe 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 Error details window Error details Common error information Reasons for system 16 switching Reason s for system 1 switching failure Individual error information Nothing Reason s for system switching 0 No system switching condition default 1 Power OFF reset hardware failure watchdog timer error 2 Stop error except watchdog timer error 3 System switching request by network module 16
353. l Relays Registers For System Switching 1 Special Relays For System Switching Special relays for system switching are shown in Table5 38 Table5 38 Special Relays For System Switching Setting at Time of System Switching Device No System switching enable disable Description Turns ON when a system switching request is issued from the network module The module No that issued system switching can be checked by New Control System New Standby CPU Module System CPU Module M1 eM iS3 flag from network SD1590 9 9 module Turns OFF when all bits of SD1590 are OFF This flag is used to determine if the new standby station detects Standby system 6210 STANDBY during system switching SM1591 error detection This applies to the following switching methods _ O disable flag at system switching e System switching from GX Developer e System switching using dedicated instruction e System switching by the intelligent function module OSet Not set 2 Special Registers For System Switching Special registers for system switching are shown in Table5 39 Table5 39 Special Registers For System Switching Setting at Time of System Switching New Control System New Standby CPU Module System CPU Module Description 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 com
354. l system Run CPU module program 1 New Standby system CPU module Synchronized Tracking Mode In synchronized tracking mode the control system CPU 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 Scan time Prepare Tracking data 2 Prepare Tracking data 1 Waiting 2 ree 1 r Error occurrence END Ts Run m Standby system CPU module END Program 2 eH 2 ian Sy Les v o o Non executed Send Send Tracking processing 1 Tracking processing 2 Receive Receive 0 Run program T RS Son pele system Adjust Tracking data 1 Adjust Tracking data 2 Because tracking processing 2 is complete adjust tracking data 2 will be performed to reflect the change in the new control system CPU module s internal device Diagram 5 51 Synchronized Tracking Mode Operation Timing 5 94 5 5 Tracking Function 5 5 7 Tracking Mode D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series b Program Priority Mode In program priority mode the control system CPU module executes the scan 2 execution type program as soon as tracking starts 2 f k S A oc If tracking time is longer th
355. l system identification flag SM1519 However if battery error has occurred in either system and device data cannot be held the operation cannot be guaranteed 1 When a Network Module is not Mounted on the Main Base Unit The following program shows the operation when the previous control system starts up with no network module mounted on the main base unit a Program Example SM1519 SP CONTSW K1 MO GOEND Diagram App 14 A program example b Operation Image 1 System B is operating as the control system Standby system System A System B ooo ooo000 puny Control system ooo ooo000 Tracking cable Diagram App 15 The system when System B is operating as the control system App 24 Appendix 5 Method for Starting up the Previous Control System APPENDICES MELSEC TAY series 2 Power supplies of both systems are temporarily OFF because of a power failure etc System A System B a ooo PROCESSING TIME FOR REDUNDANT coon SYSTEMS oooo00 ooooo0 ial Slang
356. lacement The control system power supply module cannot be replaced while redundant z systems are running When replacing the control system power supply module switch its system to the standby system by GX Developer then start the replacement operation rA O Power supply module E Control Standby 5 5 system system Q i 3 a g E LS a EE p a Bl gl E aS al BHE C SH al g HE Tracking cable 2 O Oo z xe Q GX Developer E Replace after using GX Developer to switch over to the standby system Diagram 8 18 System where Control System Power Supply Module is Replaced 2 g Replace the power supply module for the standby system after turning the power 2a supply for the standby system OFF 298 e The standby system power supply can be turned off even when the redundant system EE is active a Power supply module Control Standby system system E H EEIE S E al zo 8 H a 56 Ze al E Sl g a 36 6 gA 8 g aS a 2 re Te Tracking cable W g d Replace after turning OFF z9 GX Developer the standby system power A Diagram 8 19 System where Standby System Power Supply Module is Replaced Di 0 Z o 26 E3 ee 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 gt Section 8 3 3 o Zz Q O T o wW a O iva E 8 3
357. lection of the refresh items by the COM and ZCOM instructions Table7 4 shows the refresh items by the COM and ZCOM instructions and whether they can be selected or not in the redundant system OVERVIEW Table7 4 Refresh Items by COM and ZCOM Instructions and Whether They Can Be Selected or Not in Redundant System CONFIGURATION SYSTEM Instruction Selection in redundant Refresh item symbol system I O refresh O Network module refresh COM Auto refresh of intelligent function module x Auto refresh of CPU shared memory x TRACKING CABLE General data processing G Network module refresh on ZCOM Auto refresh of intelligent function module 2 Selectable x Not selectable 1 Tracking is not executed when the COM or ZCOM instruction is executed If system switching occurs due to any of reasons for system switching indicated in No 1 of Table7 5 from when the COM instruction or ZCOM instruction is executed until tracking is completed system switching is done without tracking being performed Hence any change made to the output to the network module by the COM ZOM instruction in the control system CPU module will not be reflected on the standby system 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 REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Table7 5 Reasons f
358. ling External Devices A redundant system controls external devices using remote I O stations remote device stations and intelligent device stations connected to CC Link b Settings of Master and Local Modules Set the CC Link master and local modules as follows 1 When mounting to the main base unit e System A master station e System B standby master station 2 When mounting to the extension base unit Set Master station Extension base c System start up 1 When using the QJ61BT11N whose first 5 digits of serial No is 07112 or later When using the CC Link control using the CC Link can be made starting up from either system A or system B When using the QJ61BT11N whose first 5 digits of serial No is 07111 or earlier When using the CC Link start up the 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 Standby Master station System A Control System System B Standby System 2 oO oO 5 gt ie el 5 5 E nN N N N N m m 8 5 aaa aaa a ET g 5 aja ry w Q 3j jajz E E 5 fale 15 5 ee a GIG G 2 E GIG G a 2 a re oO o O O oO A Tracking cable 5 CC Link 7 f Remote device Intelligent device Local station Remote I O station station station Diagram 2 7 Connection of Redundant System to CC Link 2 1
359. lowing stop error occurs in the standby system CPU module only FILE DIFF error code 6001 i If a stop error occurs in the standby CPU module the following continuation error will occur in the control system CPU module STANDBY SYS DOWN error code 6300 5 24 5 1 Basic Concept of Redundant System 5 1 4 System Consistency Check D REDUNDANT SYSTEM FUNCTIONS MELSE TA ories 5 1 5 Self Diagnostics Function 1 2 3 Self Diagnostics Function The self diagnostics function means that the redundant CPU checks for its own error in order to prevent malfunction as well as to perform preventive maintenance If an error occurs when the redundant system is powered on or while the redundant CPU is running the redundant CPU detects the error and displays it and performs system switching etc Error Detection Processing a Error detection processing When detecting an error the redundant CPU will perform the following process 1 Turning the ERR LED etc on 2 Turning the special relays SMO SM1 on 3 Storing the error information error code into the special resistor SD0 When detecting multiple errors the redundant CPU will store only the latest error code into the SDO Use the special relay and special register in a program to make a PLC 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 che
360. lso be done via special relays and special registers C gt Section 5 7 a oY Failed CPU module GX Developer 2 Transfer Standby Control system system B 1 A nooo Pee ty Iesi Deo eos Tel r Tracking cable aA UI RS 5 Fre ke D 5 ean FN Dem o o D 5 ky mE jel a Ke o D ar nn een ty Replacement CPU module 1 Replacing the CPU module 1 to 3 shows the procedure to copy parameters and programs to the replaced CPU module Diagram 1 8 Copy of Parameters and Programs when CPU Module is Replaced 1 2 Features 1 OVERVIEW MELSEC TAY series 7 Access to redundant system from host network
361. lt ZE S ee u3 u 4 ez Diagram 6 17 Network Parameter Setting the number of MNET 10H Ethernet Cards Screen Refer to the following manual for network parameters LF Q Compatible MELSECNET H Network System Reference Manual Remote I O Network Lu 2 gt no Zz lt x Q Zz Q W a n X faa O z 2 Ww Zz 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 MELSECNET H remote I O network g After starting up system A and system B the control system and standby system are o lt determined and then the data link is started ge Fs S o 5 5 fe 6 2 Redundant System Network Overview 6 19 6 2 2 MELSECNET H Remote I O network 6 REDUNDANT SYSTEM NETWORKS Mi aL 20 fel ceries 7 Detecting Configuration Mismatch for the Remote I O Station in the Master Station and Sub master Station When a disconnection occurs in the system connected to the MELSECNET H multiplexed remote I O network the accessible remote I O stations might be different between the control system master station and standby system sub master station In this case as control cannot be continued after system switching the UNIT LAY DIFF error code 6036 stop error specific to the standby system in the backup mode occurs in order to prevent system switching The abovementioned operation i e checking w
362. m System Control Standb Standb Control ue Power OFF Y y Startup as control system Switching System System System System Control Standby Standby Control Reseting Startup as control system System System System System System Switchin A 9 Control Standby Control Standby Request by Network Startup as standby system System System System System Module System Switchin Control Standb Control Standb g 7 X Startup as standby system Manual Using GX Developer System System System System System System Switching b UE i a oe Control Standby Control Standby Switching System Switching Startup as standby system System System System System Instruction 5 46 5 3 The System Switching Function 5 3 3 System Switching Execution Possibility 5 REDUNDANT SYSTEM FUNCTIONS MELSEC fA series Table5 32 When System Switching Cannot Be Executed Due to Watchdog Timer Error of Standby System System Status After System Status Before System s is hi Control System Switchin y System Switching Operation After System B Power witchin g Switching Condition g Condition OFF gt ON a Method a System A System B System A System B Stop Error Other Than Control Standby Standby Control Startup as standby system Watchdog Timer Errors System System System System Control Standb Standb Standb Watchdog Timer y 4 Startup as control system System System System System E Control Standb Standb Control
363. m 100K K word File register file settings s Target memory File name x A 2 lt woe 5 ages EE 7 Ww Se Tracking characteristics setting 8 o 2 Synchronized tracking mode T ake more scan time a e Program priority mode 5 m Diagram 5 48 Tracking Setting Screen 2 n 26 Table5 48 Tracking Setting Items and Ranges z E O Item Range Default Reference ET Internal device block settin Section Tracking device setting a Internal device block setting Device detail settings 5 5 3 e No trackin Section A Signal flow memory tracking setting 9 F No tracking E Enable tracking of signal flow memory 5 5 3 gt Section Tracking block No 1 to 64 1 Zg 5 5 5 96 7 Ds Devige Table5 44 Default Trackin Section Diy a u l Davice range Settings Points Start Table5 44 Tracking Range Set by User g ma Range 5 5 3 Start End e Synchronized tracking mode Section Tracking characteristics setting if q Synchronized tracking mode e Program priority mode 5 5 7 e Do auto forward Tracking block No 1 Do auto forward Trackin Section Z Do auto forward Tracking block No 1 9 g g e Do not auto forward Tracking block No 1 block No 1 5 5 5 22 Target Memory card SRAM Se memory Standard RAM TS File register Sets tracking file register file name file settings 2 Up to 8 half width characters File name Cannot include the following characters g lt gt E fe ae 7 W a 2 5 5 Tracking Functio
364. m configuration for the example of the REMFR instruction programming Control system Standby system Cole ola Station No 10 Station No 2 op i Target intelligent function module of REMFR instruction I O No 10H Diagram 7 1 System Configuration e Relevant devices Table7 2 indicates the devices used in the program example for the REMEFER instruction Table7 2 Devices Used for Execution of REMFR Instruction Name Module status SB47 Baton pass status of host SB48 Status of host SB49 Data link status of host SW70 9 Baton pass status of each station 10th station SW74 9 Data link status of each station 10th station Remarks Refer to the following manual for details of the link special relays SB and link special registers SW lt gt Q Corresponding MELSECNET H Network System Reference Manual Remote I O Network SM1518 Standby system to control system switching status flag M200 Read request
365. m 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 status of SM1649 to be held for one scan or longer so that the standby system will detect the SM1649 change i e SM1649 turns from OFF to ON or OFF to ON SHI510 SM1513 SM1515 SM1516 SM15600 When M0 is set to ON in the System B CPU MG NO M1000 4 af tf At 7 module Y100 is also set to ON NOZ M1000 M100 mo SH1610 rset won J When a connection error occurs in the standby system set M102 to ON SH1649 1 RST sh1649 J Set SM1649 to OFF RST spis49 J Initialize clear SD1649 RST wmo Set M102 to OFF M102 me n a The error code for standby system errors is t stored in SD1649 FSET suisag Set the standby system error clear command SM1649 to ON 20 MCR No 21 END Diagram 8 14 Sample Program for Clearing Standby System CPU Module Error 8 2 Error Clear 8 29 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS o Zz Q O T o wW m
366. m of the redundant system by making the network module redundant group settings of the Ethernet modules system switching can be disabled even if an error occurs in one network However if a communication error occurs in both Ethernet modules system switching will occur Example MELSEGC Eseries Diagram 5 90 and Diagram 5 91 show the operations when an error occurs in the communication between the control system and standby system via the Ethernet e Diagram 5 90 show the processes that take place when a malfunction occurs on one of the networks with network module redundant group settings Commu nication error Standby system System A goo oo0000 System B oomo oo0000 OPS ll Ea ecoles TY ME eoan BE Tracking cable eo Noss fg One of the modules set in the redundant group setting has requested a system switching E Control system System A 00000 goo Commu7 nication error g OPS E Control system a OPS Commu OPS nication error System A nooo Standby system System B coon no
367. m 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 Section 2 3 for details of network modules compatible for redundant system 1 12 1 2 Features 1 OVERVIEW MELSEC TA cores 2 Connection of Extension Base Unit In the redundant system where the Redundant CPU whose first 5 digits of serial No is 09012 or later is used in both systems the extension base unit can be connected 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 OVERVIEW Control system Standby system a CONFIGURATION SYSTEM Colle os ee NES Nac Tracking cable Extension cable Q65WRB a 2 TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ke For the precautions of the system configuration when connecting the extension base unit refer to Section 2 4 Diagram 1 3 System Configuration when Connecting Extension Base Unit REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS
368. m y ae UNIT LAY DIFF 6035 T x models check a6 Startup Ability z ee ETET i 5 ZE 19 Cheek Orcon rol system and standby system memory car CARD TYPE DIFF 6040 6041 BZ settings check cL 3000 to 3004 2 Parameter settings check PARAMETER EEROR me 3007 3040 3042 21 File storage to program memory check FILE SET ERROR 2400 2401 a 22 Program files check CAN T EXE PRG 2500 to 2504 A 23 Instruction codes check INSTRCT CODE ERR 4000 to 4004 z9 pA Mf o 24 Pointer P check CAN T SET P 4020 4021 29 25 Pointer I check CAN T SET I 4030 4225 D m 26 END instruction check MISSING END INS 4010 27 Link parameter error LINK PARA ERROR 3100 to 3107 28 Remote password check REMOTE PASS ERROR 3400 3401 29 Intelligent parameters check SP PARA ERROR 3300 to 3302 6 30 File consistency check FILE DIFF 6000 p 31 Parameter valid drive settings consistency check FILE DIFF 6001 22 32 Tracking setting parameter check TRK PARA ERROR 6500 6501 95 S 1 Indicates the priority of the order in which errors are detected when the both systems are powered on or the CPU modules are unreset RESET L CLR switch is set to the neutral position 2 The errors may be detected regardless the priority E 3 Can be changed to continue in the PLC parameters settings of GX Developer Z 8 ae 7 5 a oc 5 1 Basic Concept of Redundant System 5 27 5 1 5 Self Diagnostics Function D REDUNDANT SYSTEM FUNCTIONS 5 1 6 Start Mode MELSE TA ori
369. mage preventing interlock circuits such as emergency stop protective circuits positioning upper and lower limits switches and interlocking forward reverse operations 2 When the PLC detects the following problems it will stop calculation and turn off all output in the case of a In the case of b it will hold or turn off all output according to the parameter setting Q series module a The power supply module has over current protection equipment and over voltage Output OFF protection equipment b The CPU module self diagnosis functions such as the watchdog timer error detect problems Hold or turn off all output according to the parameter setting In addition all output will be turned on when there are problems that the PLC CPU cannot detect such as in the I O controller Build a fail safe circuit exterior to the PLC that will make sure the equipment operates safely at such times Refer to LOADING AND INSTALLATION in QCPU User s Manual Hardware Design Maintenance and Inspection for example fail safe circuits Output could be left on or off when there is trouble in the outputs module relay or transistor So build an external monitoring circuit that will monitor any single outputs that could cause serious trouble Design Precautions When overcurrent which exceeds the rating or caused by short circuited load flows in the output module for a long time it may cause smoke or fire To p
370. main base unit Connect OUT connector of the redundant type extension base unit to IN connector of the redundant power extension base unit wW no gt no E zZ lt z Q W a 7 2 O oO Zz 5 u REDUNDANT SYSTEM NETWORKS e The main base units used in systems A and B should be the same model Table5 15 Error description when extension base unit does not meet use condition Use condition Error description e Connect the redundant type extension base unit to the first extension stage BASE LAY ERROR error code 2012 or 2013 e Properly connect the redundant type occurs PROGRAMMING CAUTIONS extension base unit and the main base unit Only one redundant type extension base unit is applicable per system The main base units used in systems A and B EXT CABLE ERR error code 2020 occurs BASE LAY ERROR error code 2012 occurs should be the same model TROUBLESHOOTING 5 1 Basic Concept of Redundant System 5 241 5 1 4 System Consistency Check D REDUNDANT SYSTEM FUNCTIONS Mi aL 20 A ceries 5 Memory Card Setting Status Consistency Check a Check points The memory card setting consistency check means checking if a memory card is set and the type Table5 16 Memory Card Setting Status Check Points Check Points Description Memory Card Setting Checks if a memory card is set or not Checks if type of memory cards set in the control system and standby
371. manual of the used network lt module Zo p 26 no Wiring Connect the network cable to the network module Refer to the manual of the network module for connecting the network cable wW a Turn on the Standby System s Power Supply 5 1 Match the position of the standby system CPU module s RUN STOP switch with that of the control system 2 Set the control system CPU module s RESET L CLR switch to the central position 3 Turn the standby system power supply ON l Confirm the Power Supply Module s POWER LED Sa Confirm that the power supply module s POWER LED is ON green and that power is being WS 5 supplied properly a 2 6 OFS l TER r 7 ange Confirming the Network Module Status Confirm that the new network module has not developed an error by using the System Monitor of GX Developer Y 2 ZO Start standby system zg ZE Diagram 8 27 Network Module Replacement Procedure pZ Cu POINT z When the standby system is powered OFF the control system CPU module A develops in a STANDBY SYS DOWN error code 6300 continuation error 2 3 a After the replacement of the standby system CPU module is complete reset 5s errors in the control system CPU module as necessary T2 Refer to Section 8 2 for the error resetting method 0 Z o g 95 act ao o Zz Q O T o wW m O iva E 8 3 Replacing Module in Redundant System 8 39 8 3 5 Network Module Replacement Procedure 8 TROUBLESHOOTING 8
372. manually by the z user while the system is running a p e E gt 2 types of manual system switching are available system switching using GX Developer and that by the system switching instruction SP CONTSW instruction The manual system switching is performed for the control system CPU module rA re i fe a System switching using GX Developer k When executing the system switching in the control system CPU module using o P ee GX Developer the system switching operation is done at END processing 26 1 System switching using GX Developer is done in the following procedure e Turn on the Enable disable user system switching flag SM1592 in the R l control system CPU module lt e The system switching request is issued to the control system CPU module z by GX Developer remote operation k aa Sai System A as System B System A System B i 5 5 Control Standby a O S System System a g aj g a g 1 c PPR ale AF F rea E 8 ll X il f ane E E 0 RUN Control i ae fel andby Tracking cable Execute program systent system aca Viale 5 System Stop program fa Execute system System switching neg GX cr i g gt 22 switching operation Developer y o GX Developer on the control system END Sy tem i 2 S End calculation ating 1 switehing 4 E ystem A System B 1 mMm J Z Control System Standby System i za 2 Standby System Control System 1 us R J5 a i E Normal Standby Stand
373. master station to the 2 master station using the new control system s program an Refer to Appendix 4 for program details as Master Station Standby Station Station No 0 Station No 1 wW Control system Standby system z a a O i a E areare TE g BETE al ale i 3 3 Leb el oE 2 i sl aaa M 4 8 SIGE g e H A Ss 8 E E z e amp 3 Tracking cable CC Link fi Cc y E e55 204 aza Remote I O station ORS station No 2 Qe ane Master Station Standby Station z Station No 0 Station No 1 Control _ Standby Standby _ Control E T system System System x a faa e Zr S ee u3 cw 6 ieai iesikm Tracking os j o CC Link W n gt O E ae Submit SP CONTSW SS instruction a Remote O station he station No 2 Diagram 6 28 Operation When System Switching Is Manually Carried Out 0 Z o 56 22 O oO as Q fe ac i wW a oc 6 2 Redundant System Network Overview 6 31 6 2 4 CC Link 6 REDUNDANT SYSTEM NETWORKS 6 32 3 4 5 6 MELSEC TA ories Programs for Switching the Standby Master Station that Controls CC Link Refer to Appendix 4 for programs that switche
374. mie B Communicate with the control system CPU module Control System System B Standby Sy em Standby System e Select this option to communicate with the standby system CPU module using GX Developer If system switching occurs communication is done with the new standby system CPU module e If the CPU module connected to GX Developer is the standby system communication is done with that CPU module If the CPU module connected to GX Developer is the control system communication is done with the other system the standby system via the tracking cable System A Control System System B Standby System i o fs ei Standby system i B iE aj gja al he standby system CPU module tem System B Standby System J IE al el a em C System A e Select this option to communicate with system A CPU module using GX Developer If system switching occurs communication continues with the new system A CPU module If the CPU module 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
375. minator Bus terminator 00 00 DOG onon onon onononon onon0n00 onononon onononon 00 on ODO onononag 00 00 ono o0 o0 onon ononon ogon onon onononon ononon DP Slave DP Slave Control Standby system An error has system been detected New standby New control system system l Tracking cable Bus terminator 9 Bus terminator TEE 5 sss l Se ae EECA EEE EE EES 35153 83 38 88 39 85 88 35188 88 38135188 83 85 85 88 83 35 38 DP Slave DP Slave Diagram 1 6 System Configuration for PROFIBUS DP 4 Redundant system settings using parameters Redundant system settings such as tracking settings network pairing settings etc can be made easily in the parameter settings of GX Developer 1 16 1 2 Features 1 OVERVIEW MELSEC TA series 5 Writing parameters and programs to control system and standby system without the need to identify each system Parameters and progra
376. mmunication by specifying the control system of a redundant system by GX Developer and MC protocol of other networks QCPU can communicate with Redundant CPU regardless of serial No GX Developer Control system E specified MELSECNET H PLC to PLC network network No 1 gt MC protocol Control system specified Ethernet network No 4 QCPU can communicate with Redundant CPU regardless of serial No Ried d MELSECNET H PLC to PLC network network No 2 MELSECNET H PLC to PLC network network No 5 stations Relay station CPU module Serial No of CPU module E E on relay station 06051 or earlier 06052 or later 3 CPU1 x 5 CPU2 x O a CPU3 x Tracking cable O Applicable x Inapplicable Diagram 6 40 System Configuration for Communication from Other Networks with Control System Specified 6 5
377. module errors L77 Section 8 2 Is the 2 SYSTEM A B LED lit up solid 22 green go OS cz O Please contact the nearest Mitsubishi represenative reseller or branch office v and explain the fault symptoms Completed Diagram 8 5 Flow for the Case where the SYSTEM A B LED is Flashing o Zz Q O T o wW a O iva E 8 1 Troubleshooting Flow 8 9 8 1 3 When the SYSTEM A B LED is flashing 8 TROUBLESHOOTING MELSEC TE eries 8 1 4 When the System A System B CPU module RUN LED is not ON The following flow Diagram 8 6 is for the case where the System A System B CPU module RUN LED is not on The RUN LED does not light up NO Separate mode 3 Is the running mode set to backup mode 1 YES Backup mode Is the control system CPU module RUN LED not lighting up 2 Normal the standby system CPU module RUN LED is not ON NO Flashing Reset with the CPU module s RESET L CLR switch Is the RUN LED ON YES not ON Is the RUN STOP switch set to the RUN position Return the RUN STOP switch to the RUN position 1 The operation mode can be confirmed by the BACKUP LED lt _ gt CHAPTER 8 2 The control system CPU module can be identified by the CONTROL LED lt _ gt CHAPTER 8 3 When the RUN LED of the standby system CPU module is flashing in the separate mode
378. mon information category code for SD4 0 No system switching condition default Error common SD5 information 1 Power OFF reset hardware failure watchdog timer error O O 2 Stop error except watchdog timer error 3 System switching request by network module 16 Control system switching instruction 17 Control system switching request from GX Developer Stores system switching disenabling condition only when 8 System switching condition is saved to individual error information category code for SD4 0 Switch successfully completed default 1 Tracking cable malfunction cable disconnection cable malfunction internal circuit malfunction or hardware malfunction Hardware failure power OFF resetting or watchdog timer error occurring on standby system Individual error Hardware failure power OFF resetting or watchdog timer error occurring SD16 f on control system O information Preparing for tracking communication Timeout Stop error other than watchdog timer error Operations on the 2 systems are different detected only in Backup Mode Copying memory from control system to standby system 9 Writing during RUN 10 Fault detection by standby system network module 11 Executing system switching N ev Oo OO OSet Not set 5 52 5 3 The System Switching Function 5 3 5 Special Relays Registers For System Switching REDUNDANT SYSTEM FUNCTIONS MELSEC LA series Table5 39
379. mple program of MAIN Appendix 4 Sample Programs when Using CC Link APPENDICES MELSEG TA series 2 When using the QJ71BT11N whose serial No is 07111 or earlier a Sample Program Name CHANGE 1 Sample program overview flow Set 141 to be valid Forcibly change the system that Step 0 to 11 communicates with the CC Link PROCESSING TIME FOR REDUNDANT SYSTEMS Step 70 to 73 IRET APPENDICES Refresh the remote devices and enable system switching Step 12 to 33 Initialize devices at the time of system switching Step 34 to 37 INDEX Refresh the CC Link Step 38 to 54 Perform system switching when system B starts up as the control system Step 55 to 68 FEND Diagram App 10 Sample program overview flow Appendix 4 Sample Programs when Using CC Link App 21 APPENDICES MELSEC TA eries 2 Sample Program SM402 FMOV HOFFFF DIO0 K8 J SM1518 mov H200 Do2 J A ro 4 Adds 141 to the allowable interrupt defaults 10 g to 131 148 to 1255 9l IMAask Di0 J 11 EI 1 sm4oo y ua J 12 BMOV K4Y1000 6352 K10 4 Performs a refresh of RY Y1000 to Y109F E ua 2 BROW 0220 ARAAIOOOS R10 4 Performs a refresh of RX X1000 to X109F U4 BMOV 1100 G480 Ko J Performs a refresh of RWw W1100 to W1113 U
380. ms can be written into both of control system and standby system using GX Developer There is no need to identify each system gt Section 5 6 1 OVERVIEW Gontro system Standby system z it Lind m k ml 5 0 8 E HB i A el E A 26 a e Ho 2 Bil nao z e eH z e amp Tracking cable 2 3 z a lt O Oo zZ xe Q 1 to 3 denotes the process up to writing E 1 Execute PLC Write 2 Write to Control system GX Developer 3 Write to Standby system e PX Developer 2 lt ae Diagram 1 7 Writing to the Control System and Standby System by Download to PLC a 26 a oe W E n a a Zo 56 Ze 2 S Ei wW D GEE W E n a 22 ence ZO Ze lu W Pe ms 0 Z 2 no E O oO zZ E Q fe ae N a oc E 1 2 Features 1 17 1 18 OVERVIEW MELSEG TA eerie 6 Copy of parameters and programs from control system to standby system After the CPU module is replaced in standby system parameters and programs can be copied from the CPU module of control system to the new CPU module by executing the transfer command from GX Developer This operation can a
381. munication 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 MELSECNET H PLC to PLC network Normal Normal station Station No 3 Normal Normal station station ation No 3 pan eo a Control station Standby system Tracking cable Diagram 6 7 Communication between Control System and Standby System Network Modules 6 2 Redundant System Network Overview 6 2 1 MELSECNET H PLC to PLC network 6 REDUNDANT SYSTEM NETWORKS MELSE Eseries
382. munication error occurs in a network other than CC Link system switching occurs and the new control system takes over the control of the redundant system However the new standby system master station does not switch to the standby master station as it can communicate with remote stations Also the new control system standby master station remains as the standby master 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 Station number used for the network MELSECNET H PLC to PLC network Master Station Standby Station Station No 0 Station No 1 System A System B Control System Standby fa g i Tracking cable o CC Link Remote I O station station No 2 J i Station number used for the network MELSECNET H PLC to PLC network gt Master Station Standby Station Station No 0 Station No 1 SystemA System B Control System Standby System IR o Communication no
383. n Does not execute output Continues execution Continues execution Continues execution Does not execute refresh No change from before operation mode change Continues execution Continues execution Continues execution Does not execute refresh No change from before operation mode change Continues execution Continues execution Continues execution Continues execution Continues execution Does not execute auto refresh Continues execution Does not execute auto refresh Continues execution Continues execution Continues execution Does not execute refresh No change from before operation mode change AG Q series 5 4 Operation Mode Change Function 5 65 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol wW wn gt 2 Zz lt j zZ W ve 7 2 Q oO 2 5 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS Redundant function 5 66 MELSE LA series Table5 41 Operations When Changing Operation Mode Continue Function Data tracking Refer to Section 6 2 2 for details Device memory Backup Mode to Separate Mode Standby system oe bo Continues execution SM SD system dependent Stops tracking SFC information St
384. n 5 5 4 Tracking Data Settings D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 5 5 5 Tracking Block And Tracking Trigger 1 Tracking Blocks a oc a Tracking Block Overview 3 The internal device tracking range can be divided into multiple blocks i e tracking blocks tracking block No 1 to 64 at the tracking settings in the redundant parameter settings of GX Developer z O b Tracking the Tracking Blocks Set whether the tracking block will be tracked or not with the data tracking block ae specification trigger SM1520 to SM1583 that corresponds to the target tracking 58 block When the data tracking block specification trigger is turned ON the device data set to the corresponding tracking block No will be tracked i Program Example 2 z E SM1521 H Transfer Tracking Block 2 f SM1522 Transfer Tracking Block 3 e a 9 lt p55 Sza Operation TEE END Processing END Processing END Processing END Processing 5 i Program Program Program Program I TS are TE oal i A ON 5 9 SM1520 go 20 a5 cw smi521 OFF ON fi S1522 OFF ho 5 T 1 ence i 29 QF Tracking data Block 1 Block 1 Block 1 Block 1 wy Block 2 Block 2 Block 2 Block 2 Block 3 Block 3 Diagram 5 49 Tracking Operation Timing by Tracking Trigger 5 6 95 ot O g Z E Q fe ae 7 Ww a oc 5 5 Tracking Function 5 87 5 5 5 Tracking Blo
385. n 5 85 z 5 5 4 Tracking Data Settings D REDUNDANT SYSTEM FUNCTIONS 5 86 MELSE TE ories 1 The following is the setting range in the detailed device settings 1 to 2048 devices can be set for one block The total of the number of devices for all blocks is 2048 maximum The device range settings for the timer retentive timer and counter device will be doubled Tracking device capacity per block is up to 100k words including single flow memory tracking capacity 16k words Tracking device points per range are Bit device 0 to 32767 set in 16 point units Timer retentive timer and counter 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 E 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 GX Developer 2 As 100k words can be set in one block and up to 64 blocks can be set up to 6 400k words can be set as a total at the tracking settings in the redundant parameter settings of GX Developer However up to 100k words can be tracked for each scan When setting tracking data to multiple tracking blocks make sure that tracking capacity is within 100k words for each scan 5 5 Tracking Functio
386. n SD1596 of the control system CPU Tracking cable disconnection 5 124 E MELSOFT application j The tracking cable has a communication problem J Please execute it again after confirming the state of the tracking cable lt ES5 010a4242 gt 4242H will be stored in SD1596 of the control system CPU 5 7 Memory Copy From Control System To Standby System D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 5 8 Online Module Change Hot Swapping In the redundant system following modules can be replaced online e Module mounted to the extension base unit I O module analog module etc e Module mounted to the remote I O station in the MELSECNET H Remote I O network I O module analog module etc e Power supply module when the power supply modules are duplicated e I O module mounted on the main base unit where the Redundant CPU is mounted Only when the extension base unit is not connected OVERVIEW CONFIGURATION SYSTEM The network module mounted on the control system main base unit cannot be replaced online while the system power is ON When replacing the network module mounted on the control system main base unit make sure to switch it to the standby system using GX Developer or the system switching instruction SP CONTSW instruction The standby system is not actually controlling Therefore there will be no effect on the redundant system control if the standby system is powered off When poweri
387. n base unit of control system and IN1 IN2 connector i by extension cable a 3 Oo zZ xe Q x fue Are main base unit of standby system and Q65WRB connected Turn OFF power supply of standby system z by extension cable x p o LIN woe Connect OUT connector of main base unit 8 T 2 of control system and IN2 IN1 connector Ela e of Q65WRB by extension cable Turn ON power supplies of control system and standby system again 2 n Turn ON power supply of standby system 2 209 56 ZE S A wW D GEE W Ee n a Does EXT CABLE ERR Eo occur again F Be re Hardware failure of the following modules is suspected CPU module Main base unit or extension base unit Extension cable Consult your local Mitsubishi service 0 Completed representative explaining a detailed p description of the problem z9 RO OF E O Diagram 8 10 Flowchart for when EXT CABLE ERR occurs As for IN1 connector and IN2 connector of the redundant type extension base unit connect one to the control system and connect the other to the standby system o Zz Q O T o wW a O iva E 8 1 Troubleshooting Flow 8 241 8 1 9 When ETX CABLE ERR Occurs 8 TROUBLESHOOTING MELSEC TE ories 8 1 10 When BASE LAY ERROR Occurs The following shows the flowchart for when BASE LAY ERROR occurs during operation of the redundant system Error message BASE LAY ERROR was detected
388. n specifying standby system using MC protocol b Diagram 6 31 Operation for Communication with Standby System CPU Module by MC Protocol TROUBLESHOOTING 6 2 Redundant System Network Overview 6 2 5 Serial Communication Modules 6 37 6 REDUNDANT SYSTEM NETWORKS Mi aL 26 fel ceries 3 Communication between External Devices and System A System B a Communication by MC Protocol In order to perform the communication with the system A system B CPU module specify System A or System B on each external device by MC protocol If System A or System B is specified by MC protocol communication with the specified system CPU module can be performed even when system switching occurs This communication can be performed by MC protocol only Multiplexed Remote Master Station Multiplexed Remote Sub master Station System B Standby System System A Control System ooo000 Tracking cable Remote I O module Serial communication module
389. n system switching occurs the control system CPU module turns on signal flow memory in all steps Therefore the rise instruction for which SM1518 has been set as its execution condition cannot be executed after system switching SHI518 H DUTY KI K3 SM420 l i After system switching startup execution instructions are not run Diagram 7 4 Program for DUTY Instruction Using SM1518 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 instruction will be executed upon SM1518 fall SM1518 W After system switching perform DUTY instruction during M1518 shutdown 0 DUTY KI K3 SM420 Diagram 7 5 Program That Executes DUTY Instruction on the Falling Edge of SM1518 b Relevant Instructions e PLS P Examples MOVP INCP etc SP O GP 9 ZP 9 JP g Intelligent Function Module Dedicated Instructions 7 6 7 1 Instructions Restricted in Use for Redundant System PROGRAMMING CAUTIONS MELSEC LA series 7 Restrictions on Use of COM and ZCOM Instructions The COM and ZCOM instructions execute refresh between the Redundant CPU and network module during program execution In a redundant system there are restrictions on the se
390. n system switching occurs in a redundant system When connecting a redundant system to the CC Link create the sample program shown in Appendix 4 5 Appendix 4 1 Sample Program System Configuration The system configuration is shown below for the sample program which sets the network parameters for CC Link In the diagram below the I O Nos X Y40 to X Y5F are assigned to the CC Link master local modules L Section 2 4 If the system being used is different from the diagram Diagram App 1 change the settings for the sample program device Nos and for CC Link network parameters Master Station Standby Master System A Prefix 0 System B Station Prefix 5 Control System Standby System joa j g g o gl g a ale a ale gl 3 JE B 5 B B EH Input Output Input Output Digital Analog unit unit Converter Unit Tracking cable CC Link Remote I O Remote I O Remote Device station Prefix 1 station Prefix 2 Station Prefix 3 Diagram App 1 Sample Program System Configuration 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
391. n the new control system CPU module at system switching mya Tracking is executed o H H F10 F10 is turned on after system switching 3 HH Fit F11 is turned on after system switching REDUNDANT SYSTEM FUNCTIONS 6l ENO Diagram 7 14 Program That Turns on the Annunciators by the OUT Instruction after System Switching b When turning on the annunciators by the SET instruction By creating the following program and tracking the SET instruction execution condition the annunciators can also be turned on in the new control system CPU module at system switching REDUNDANT SYSTEM NETWORKS __ x Tracking is executed aes Sal or Re F10 is turned on at the second scan SM1518 ON OFF after att idle system switching thk SET FIL F11 is turned on at the second scan SM1518 ON OFF after n system switching 3 END Diagram 7 15 Program That Turns on the Annunciators by the SET Instruction after System Switching ku SM1518 is a contact that turns on in the new control at occurrence of system switching and remains ON for one scan Z o eo g Siel ET EO TROUBLESHOOTING 7 3 Precautions for Using Annunciator F in Redundant System 7 15 PROGRAMMING CAUTIONS Mi aL 26 Q ccries 7 4 Precautions at System Switching Occurrence 1 Precautions regarding access to intelligent function module and external device Depending on
392. nal block connector from the I O module m z J O 5 Oo Replace the Standby System s I O Unit z 1 Disconnect the I O module from the main base unit z 2 Mount an alternative I O module the same model as the control system I O module to the main ze base unit Refer to the QCPU Module User s Manual Hardware Design Maintenance and Inspection for mounting removing the I O module aa A 2 lt l p55 Mounting the Terminal Block Connector to I O module aZ6 Mount the terminal block connector to the I O module 8 T 2 a Turn on the Standby System 1 Align the position of the standby system CPU module s RUN STOP switch with that of the control s system RUN STOP switch E 2 Set the standby system CPU module s RESET L CLR switch to the central position reset switch 2 neutral position 22 3 Turn the standby system s power supply ON 45 a5 J co Confirm the Power Supply Module s POWER LED Confirm that the power supply module s POWER LED is ON green and that power is being supplied properly Hi 2 4 2 22 Start standby system 26 Q Diagram 8 24 I O Module Replacement Procedure u m POINT 0 When the standby system is powered OFF the control system CPU module develops in a STANDBY SYS DOWN error code 6300 continuation error Zg OF After the replacement of the standby system CPU module is complete reset 35 O errors in the control system CPU module as necessary Refer to Section 8 2 for the error resetting method
393. nction may occur due characteristic deterioration wire breakage etc Tracking cable 89 3 3 52 73 0 2 87 R Bending Radius When connected 27 6 1 09 or more Unit mm inch Diagram 3 1 Minimum Bending Radius of a Tracking Cable E lt POINT 1 Be sure to connect or disconnect the tracking cable after powering off the standby system or setting the RESET L CLR switch of the control system CPU module to the RESET position 2 Make sure to connect or disconnect a tracking cable by holding the cable connector 3 2 3 3 Connecting and Disconnecting a Tracking Cable TRACKING CABLE MELSE Eseries 2 Connecting a Tracking Cable z a Make sure that you are using the correct tracking cable connector for System A or System B z Refer to Section 3 2 and 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 z O Redundant CPU z P TRACKING connector z9 oO Z Connector Tracking cable Ww a m lt 6 o Z X QO lt cc E Diagram 3 2 Checking the Connection Orientation of the Tracking Connector c Connect the tracking cable connector to the CPU module TRACKING W connector 5 E Pa Redundant CPU woe
394. nd data set 2 W O signal Table App 34 List of I O Signal 3 Buffer memory Table App 35 List of Buffer Memory Buffer memory address Hexadecimal decimal O signal E Signal name Description CH1 side CH2 side Transmission normal Xn0 Xn7 ON Normal completion completion Transmission abnormal Xn1 Xn8 ON Abnormal completion 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 Walchdod timet error ON Module error occurred X n 1 F 9 OFF Module being normally WDT error operated Yno Yn7 Transmission request ON Requesting transmission Stored value CHE side 0 4 0 1401 Communication error clear 0 OFF No initialization request 3 i request and to turn LED off 1 OFF Initialization requested 0 Word units 96p 150 1364 310 Word byte units designation 1 Byte units Buff h 4004 to 1AFF A0 160 140 320 uffer memory head H H address for on demand 2600 to 3FFFy A14 161 141 321 On demand data length 0000 to 3400 LED ON status and 0 Turned off OFF no error 20114 513 eae communication error status 1 Turned on ON error 0 Completed normall 2561 598 2661 614 On demand execution result p y 1 or later Error code App 42 C00 to 1AFFy 3072 to 6911 User free area Appendix 6 Precautions for Using Serial Communi
395. ndby System Error Clear Enabled x Standby System Error Clear Disabled Irrelevant as Standby System Does not Exist 2 When the corresponding error code is stored in SD1649 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 can be simultaneously cleared Example If errors that correspond to error codes 2100 and 2101 occur both of them will be simultaneously cleared even when either one is cleared In the case of errors that correspond to error codes 2100 and 2111 both of them will not be simultaneously cleared even when either one is cleared 8 28 8 2 Error Clear 8 TROUBLESHOOTING MELSEG LAY series 3 If an error is caused by other than the CPU module relevant problem its cause will not be removed even when the error clear is performed using SM1649 and SD1649 Example The cause of the SP UNIT DOWN error cannot be removed by performing error clear using SM1649 and SD1649 as the error occurs in base unit including extension cables network module etc Remove the cause of the error by referring to the error code list 4 If the cause of the error is not removed after error clear has been performed the same error will be detected 5 Error clear processing is performed by END processing Therefore an error cannot be cleared unless the END instruction is executed with SM1649 ON c Sample Progra
396. ng 2 53 0 i END F 0 program END 0 a Control system bee Zz CPU module t m m senic senic ee ee J Tracking 4 Tracking g processing 1 processing 2 Sa TZ Receive Receive ze o5 ct 5 5 ES Standby system m CPU module I a Adjust Tracking Adjust Tracking fe data 1 data 2 Q Diagram 5 53 Tracking Operation Timing When Program Execution Time lt Tracking Processing Time P z oc E 5 5 Tracking Function 5 95 5 5 7 Tracking Mode D REDUNDANT SYSTEM FUNCTIONS 3 Asynchronous Tracking Mode In this mode the control system CPU prioritizes program operation over tracking processing If the previous tracking is not complete while executing the END processings the control system CPU module suspends the next tracking and starts the program operation MELSEC TE ories a Tracking when Control System is in RUN Standby System is in STOP and System is in Backup Mode 1 tracking when program run time 2 tracking time Prepare Tracking Error occurrence END F 9 Non executed Send 4 Tracking processing 3 Scan time Prepare Tracking Prepare Tracking Gala data 1 data 2 Control system Run te Run P Run END END END CPU module program 1 0 program 2 9 program 3 i a lt New Standby system 5 9 CPU module Send Send 4 Tracking 4 Tracking processing 1 processing 2 Receive Receive Receive Standby system CPU module 4
397. ng the standby system OFF the STANDBY SYS DOWN error code 6300 continuation error will occur in the control system CPU module TRACKING CABLE 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 that can be replaced online refer to Section 2 4 For replacing modules where the extension base unit is connected online refer to the following manual lt QCPU User s Manual Hardware Design Maintenance and Inspection REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol W wn gt n Zz lt j zZ gt W oe 2 Zz O oO Z u 2 Module Mounted on the MELSECNET H Remote I O Station The MELSECNET H remote I O station is compatible with online module change If a module mounted on the MELSECNET H remote I O station develops an error the module can be replaced without stopping system control However the target module of online module change is restricted Refer to Section 2 4 5 for details Refer to the following manual for information on online change of the module mounted on the MELSECNET H remote I O station lt gt Q Corresponding MELSECNET H Network System Reference Manual Remote I O network REDUNDANT SYSTEM NETWORKS K gt User s Manual of the corresponding module PROG
398. nit 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 e The main base units used in systems A and B should be the same model e Configuration of multiple CPU system is not allowed Turning OFF power supply reset operation of the control system is not allowed at separate mode e Boot operation of the Redundant CPU whose first 5 digits of serial No is 09011 or earlier using the memory card where network parameters for the configuration which uses Ethernet and CC Link for the extension base unit is not allowed e Disconnecting an extension cable is not allowed while the power supply of the power supply module mounted on the main base unit is ON e When interrupting from the intelligent function module mounted to the extension base unit an interrupt pointer cannot be used If set CAN T EXECUTE I error code 4225 occurs at the time of start up For the command applicable in MC protocol via a module mounted on the extension base unit refer to Appendix 7 MELSOFT products connectable to 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 lt gt GX Developer Version 8 Operating Manual lt gt PX Developer Version 1 Operating Manual Programming Tool 2 4 System Configuration Cautions
399. nnected to it via a tracking cable When using the network diagnostics to access the network module of the other system re connect GX Developer PX Developer to the other system CPU module Communicating with a CPU Module via a Tracking Cable cols ISols1 esie ese eou eos CC Link GX Developer Diagram 6 3 Communication with CPU Module via Tracking Cable Accessing a Network Module via a Tracking Cable CC Link Master Local Module Control system Standby system ooo000 oo00 ooo000 e Cols s Cole EA colled CO 1E9 i Ey Li I 42 I a C9 Tracking cable i CC Link oe 1S O GX Developer V Diagram 6 4 Access to Network Module via Tracking Cable m 6 4 6 1 Communication with GX Developer and PX Developer 6 1 3 Cautions on Access from GX Developer and PX Developer 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series 2 Corrective Action when a Line Down Occurs during Access via a Network OVERVI
400. nning T jag o J0 Control system Standby system PZ l 58 E Jere 3 8 g wW a q O Oo Tracking cable Q Replace the tracking cable after powering off the standby system or while keeping i the standby system CPU module reset Diagram 8 31 System where Tracking Cable Replacement x b E woe E SES oo W D D BO 56 Ze 2 S Ei wW D GEE W D d A Ax 2O Be lu W Pe ms 0 Z o 26 E O o Zz Q O T o wW a O iva E 8 3 Replacing Module in Redundant System 8 45 8 3 9 Tracking Cable Replacement 8 TROUBLESHOOTING M BLS AG Qa 2 Replacement Procedure The procedure of replacing the tracking cable is shown in the Diagram 8 32 Power OFF the Standby System Power off the standby system Or set the RESET L CLR switch to the RESET position reset Tacking Cable Replacement Disconnect the tracking cable from the control system CPU module Refer to Section 3 3 for disconnecting the tracking cable Disconnect the tracking cable from the standby system CPU module Connect the tracking cable connector to the standby system CPU module Refer to Section 3 3 for disconnecting the tracking cable Connect the tracking cable connector to the control system CPU module l Confirm that the RUN STOP switch of the standby system CPU module is in the same position as that of the control system CPU module Power on the control syst
401. not execute clear request of receive data during communicating data with the external device since data communication is discontinued when clear request is performed to the receive data Appendix 6 Precautions for Using Serial Communication Module App 32 APPENDICES MELSEC TA cores The program example of clearing receive data is shown in Diagram App 24 For the I O signal is X Y80 to X Y9F PROCESSING TIME FOR REDUNDANT n W X23 0 PLS M15 2 Accepts the receive M15 i data clear request BIR i E M16 M16 M11 M12 M17 M18 1X83 X84 Requests the receive o 5 H i H To H8 HOA8 K1 K1 Idata cear Q FNR i a r Turns ON the receive z LSET MVE data clear completion flag M17 A Reads the receive 18 FROM H8 HOA8 DO K1 J data clearstaius DO KO RST M16 Resets the receive ii data clear flag Z RST M17 i SET M18 J i4 H K10 i 30 a T100 Makes the 100ms data 1 communication to be i disabled after 1 is T100 i i changed into 0 RST M18 qi MA ETE paren E S cee E E cee at eho S EA teen E S ieee eee ene occa ae tos M16 M17 M18 37 _F AF 3 M19 eoon i 2 a Diagram App 24 Program Example 1 When using the Q series C24 function version A add the dotted line to the sequence program 2 Communicate data when M19 is ON Appendix 6 Precautions for Using Serial Communication Module Ap
402. nstruction will be executed after system switching e SCJ instruction If the execution condition is on during system switching the SCJ instruction will jump to the specified pointer without waiting 1 scan 2 Signal flow memory tracking capacity Signal flow memory as much as program capacity will be tracked Ol wW no gt 2 E zZ lt z a W a 7 2 Q O 2 Le REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 5 Tracking Function 5 81 5 5 3 Tracking Data D REDUNDANT SYSTEM FUNCTIONS Mi aL 20 fel ceries 2 Automatic Tracking Data Automatic tracking data is the data that the redundant CPU tracks regardless of the redundant parameter tracking settings The data settings cannot be changed by changing the redundant parameter tracking settings This applies to the SFC data PID control instruction data some special relays and special registers a SFC data SFC data is necessary for continuing the SFC program SFC data is tracked when using the SFC program in the backup Mode b PID control instruction data PID control instruction data to be automatically tracked is the data that is specified for PID control by the PIDINIT and S PIDINIT instructions The PID control data is tracked when executing the PIDINIT and S PIDINIT instructions in the backup mode 5 82 5 5 Tracking Function 5 5 3 Tracking Data 5 REDUNDANT SYSTEM FUNCTIONS Mi aL 3G Kel
403. nternal device 48k Word Setting Time Internal device 48k Word Setting Time APPENDICES Synchronized Tracking Mode 41 ms l Tracking Time Performance e Batch Transfer Mode 68 4 ms Program Priority Mode 21 ms Repeat Mode 34 2 ms System Switching Time Tsw 21 T Trc Refer to Section 9 2 300ms A Series Modules N A Applicable QnA Series Modules N A Applicable alls Auto Refresh Applicable Maximum 4 Modules NA Performed using FROM TO x Setting instruction a lt lt First 5 digits of serial No is 09011 or earlier gt gt 11 modules Main base unit only System Modules which are not duplicated are mounted Configuration Maximum Number of to MELECNET H remote I O station Number of vecus Mounted on Main mountable modules on remote I O station 64 58 Modules main base unit extension Extension Base Unit modules per station Speen eee lt lt First 5 digits of serial No is 09012 or later gt gt Up to 63 modules Main base unit extension base unit 7 stages 1 Q4ARCPU repeat mode results in program priority mode on QnNPRHCPU Appendix 1 Comparison of Q4ARCPU and QnPRHCPU App APPENDICES MELSEC LA series Table App 1 Comparison of Q4ARCPU and QnPRHCPU Redundant Systems Continued Item QnPRHCPU Redundant System Q4ARCPU Redundant System lt lt First 5 digits of serial No is 09011 or earlier gt gt N A Modules for the expanded syst
404. nternet module is mounted to the extension base unit 6 24 6 2 Redundant System Network Overview 6 2 3 Ethernet 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series 1 Overview of Communication with External Devices z a Communication by MC Protocol and Data Link Instructions For MC protocol external devices can communicate with the specified system z i e control system standby system system A or system B b Communication by Fixed Buffers and Random Access Buffers For fixed buffers and random access buffers external devices can communicate z with the control system Ethernet interface module only as processing via z sequence programs is necessary o ae as 2 External Device Operation at System Switching When system switching occurs in a redundant system external devices operate differently according to the communication method wW a In the case of OPS connection 5 When system switching occurs in a redundant system the OPS automatically 2 switches the connection path and continues the communication Z Example Diagram 6 22 shows the external device operation when the control system E Ethernet interface module detects a communication error g b X lt OPS woe ass OES m 3
405. nterrupt points Single CPU System Applicable Debug mode only Applicable 2 MELSECNET H network system remote I O stations have a limit for the maximum number of parameters that can be set with GX Configurator as intelligent function modules The maximum number of parameter settings for initialization settings 512 The maximum number of parameter settings for automatic refresh settings 256 App 2 Appendix 1 Comparison of Q4ARCPU and QnPRHCPU APPENDICES MELSEC LA series Table App 1 Comparison of Q4ARCPU and QnPRHCPU Redundant Systems Continued Item QnPRHCPU Redundant System Q4ARCPU Redundant System Bus gt N A Applicable Connection CPU Direct Applicable Communication with the CPU module Applicable Connection connected to the GOT only Computer Link is i i N A Applicable Connection MELSECNET H Remote F f GOT Station Applicable N A for extension base unit Applicable Connection c Type onnection CC Link Applicable Applicable Connection MELSECNET H PLC to PLC Applicable N A for extension base unit Applicable Network SS Connection Configuration EEFE i Applicable Applicable Connection Disabled Slot 1 becomes I O number 0 Mounting I O module or Mount I O modules and network modules on slots Enabled network module on slot 0 1 and later 16 character LED display N A auto diagnostics f Auto diagnostics error information and
406. ntrol METAL gt 109 MELSAP L Edition Hi Q Instruction Instruction Instruction A 6 Confirmation of usage of ea sequence instructions basic instructions application Details instructions etc z a q Confirmation of dedicated S instructions for PID control Details 3 E Confirmation of dedicated instructions for process control Details z fe Confirmation of MELSAP3 s wi SS 5 system configuration A a oa ae performance specifications Details fa T a oc W functions programming Ln debugging and error codes Confirmation of the Q programming method pi specifications functions etc Details A F F required for SFC programming zZ 2 of the MELSAP L type z E paa Confirmation of the jasi Tr programming method of the Details structured text language W E no gt N a 22 Ax ZO Ze lu W Pe ms 0 Z o 6 95 act O oO zZ E Q fe ae N a oc 1 OVERVIEW MELSE TA eries 1 1 Redundant System Overview A redundant system offers improved system reliability as it consists of two basic systems each of which includes the CPU module power supply module network module 3 and others so that even if a module error occurs in one basic system the other one continues the system control To configure a redundant system prepare two sets of systems i e two redundant main base units on which the abovementioned modules are mounted Then connect the CPU modules
407. nual for details of the PLC RAS setting L gt 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 g parameter dialog box E Refer to the following manual for details of the I O assignment detailed setting Q i QCPU User s Manual Function Explanation Program Fundamentals A 8 6 2 Redundant System Network Overview 6 21 6 2 2 MELSECNET H Remote I O network 6 REDUNDANT SYSTEM NETWORKS Mi aL 20 fel ceries b Operation when error occurs in remote I O station Table6 4 Operation When Error Occurs in remote I O station Settings of operation mode for Data link operation of error occurrence Redundant CPU Output operation from remote MELSECNET H remote I O P P i Redundant Remote I O control status 1 0 station network CPU station Stop Depends on the output mode Stops control All stations stop data link hold clear settings for error Continue Stop error occurrence 4 The faulty station is disconnected The output of the faulty station from the system follows the hold clear setting in Stop Continues control i Continue The other stations continue the error time output mode 4 Continue error normal data link All stations output normally Continue All stations continue data link All stations output normally 4 Set the output mode for error
408. o keep them consistent OVERVIEW Write to the control system and standby system is executed in the following conditions e Writing to the CPU module that is in STOP status gt gt Section 5 6 1 e Writing to the CPU module that is running C gt Section 5 6 2 5 6 1 Writing to the CPU Module in STOP Status CONFIGURATION SYSTEM 1 Operation When Writing to CPU Module in STOP status When writing 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 operation on the assumption that GX Developer is connected to the standby system Write of program B to the control system and standby system is executed in the order 1 and 2 TRACKING CABLE Standby system Control system nooo nooo ooo REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A g g ola Sols Ol ols 60COUz O hjer Tean T a if com Col Cols leale
409. ocsosoococosososose 5 43 5 3 4 Both Systems Operations After System Switching eeeeseseseesssesesesesosocosocosososososososeoeoee 5 50 5 3 5 Special Relays Registers For System Switchinge eeeseesesesesssssssesesosecocococosocccececeseceoee 5 52 5 3 6 System Switching Precautions s seseseeeeeeeeseseeeeosecosososososooosooosososococococosocesososesecesee 5 55 5 4 Operation Mode Change FUNCtion e eeeeeseeeeeeeeeseseeceeccecececeococesesoseseoosososoosossosssssossseoee 5 57 5 5 Tracking Function CO00OOOOOOOOOOO00000000000000000000000000000000000000000000000000000000000000000000000000000000000 5 74 5 5 1 Tracking Function Overview COO OOOOH OOOO OOO OOOO OOOO OOO OOOH OOOOH OOOOH OOOOH OOOOH OOOOH OO OOSOH OOO OOOO OOOOOOO 5 74 5 5 2 Tracking Execution ProcedurEe esccccccocoocoooocooocoooooooo0000000000000000000000000000000000000000000 5 77 5 5 3 Tracking Data OOOO COOOL OOO COOOL OOOO OOO OOOO OOO OOOO OOO OOOO OOOOH OOOOH OOOO OOO OOOO SOO OOOO OOO OOOO OOO OOO OOOO OOOOOOOOS 5 78 5 5 4 Tracking Data Settings SOOO OOOOH OOO OOO OOOOH OOOO OOS OO OOOOH OOOO OOOOH OOO OOOOH OOS OOOO OOOOH OOSOO OOOO OSOHOOOOOOS 5 85 5 5 5 Tracking Block And Tracking TrigGereeecccecccccccccccccccccccccccscccccccccccccccccscccoocsccccocscccse 5 87 5 5 6 Tracking Execution eesecscccccocccoocoooooo0000000000000000000000000000000000000000000000000000000000000000 5 91 5 5 7 Tracking Mode COO COO COOOL OOOO OOOOH OOO OOOO OOO OO OOOO OOO OOOO OOO
410. odule An error does Link direct device JL L Inexecutable Inexecutable Inexecutable not occur i SM1593 OFF Intelligent function module a Executable Executable Inexecutable Stop error FE ULAG 5 ATEND Buffer memory batch z9 Monitor monitor device batch Executable Executable Inexecutable Inexecutable 4 o5 processing ae monitor Do Pe me Dedicated Dedicated At instruction Intelligent function module 3 5 9 9 i Inexecutable Inexecutable Inexecutable Inexecutable instruction instruction execution UL GL 1 MELSECNET H network module cannot be mounted to the extension base unit 2 An error code 4248p is returned to the request source when system switching occurs during o monitoring 5 3 An error OPERATION ERROR 4122 occurs 22 4 Accessing to a module mounted on the extension base unit from the standby system is disabled BS When buffer memory batch monitor or device batch monitor is executed from GX Developer the ES following message box is displayed 1 When executing buffer memory batch monitor 2 When executing device batch monitor MELSOFT series GX Developer MELSOFT series GX Developer ES S BD Te tars LD aar 9 a a oc 5 11 Access to Module Mounted on Extension Base Unit 5 141 5 10 2 Remote Operation for Redundant System D REDUNDANT SYSTEM FUNCTIONS Mi aL 20 fel ceries Memo 5 142 5 11 Access to Module Mounted on Extension Base
411. odule the same model as the control system CPU module to the main base unit Connect the CPU module battery connector to the battery connector pin Refer to the QCPU User s Manual Hardware Design Maintenance and Inspection for removing mounting the CPU module and battery connection l l Connect the tracking cable connector to the standby system CPU module Refer to Section 3 3 for connecting the tracking cable l Power ON the Standby System 1 Confirm that the POWER LED of the power supply module is ON lit green and the module is Set the RUN STOP switch of the standby system CPU module to the STOP position Set the RESET L CLR switch of the standby system CPU module to the central position reset switch neutral position Power on the standby system Confirming the POWER LED of the Power Supply Module being properly powered l Executing the Memory Copy from Control System to Standby System Perform the memory copy from control system to standby system using the GX Developer connected to the control system CPU module and write the memory content from the control system CPU module to the standby system CPU module l Resetting the Stadndby System CPU Module Set the RESET L CLR switch of the standby system CPU module to the RESET position Setting the Switch of the Standby System CPU Module to That of the Control System Set the RUN STOP switch of the standby system CPU module to the s
412. odule and execute the instruction Enable manual system switching sm1592 p Process Block 1 SP CONTSW K1 M1 Process Block 2 SP CONTSW K2 M2 Process Block 3 SP CONTSW K3 M3 System A System B Stopping Calculation System A System B Control Standby gt System System B g 1 B 1 i 1 E Q RUN Control i Execute program system Standby Normal Standb y Tracking cable system RUN The system Stop program ae swiching i System switching instruction is f executed y 1 END System i Begin Smiti hing System A End calculation System B calculating z Control System Standby System gt i Standby System Control System g 3 EI Normal Standby Standby E E RUN 4 system Control RUN o x Stop program system Execute program L d f a i ol 1 Tracking cable J C Y m Diagram 5 28 System Switching Operation by System Switching Instruction 1 Refer to the following manual for details on the system switching instruction QCPU Q mode QnACPU Programming Manual Common Instructions 5 38 5 3 The System Switching Function 5 3 1 System Switching
413. odule is OFF Confirm that the ERR LED of standby system CPU module is ON Confirm that the error cause is OPE MODE DIFF error code 6010 5 using the System Monitor or diagnostics of GX Developer If the error is caused by the parameter or programs related to other than OPE MODE DIFF correct the parameters or programs of system A and system B Running Control System System A CPU module Set the RUN STOP switch of control system CPU module the CONTROL LED is OFF to the RUN position and confirm that the RUN LED of CPU module is ON Confirm that the ERR LED of control system 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 If the error is caused by the parameter or programs correct the parameters or programs of system A and system B 1 Power off system A and system B or simultaneously set the RESET L CLR switches of CPU modules to the RESET position 2 Simultaneously power on system A and system B or simultaneously set the RESET L CLR switches of CPU modules to the reset switch neutral position l Diagram 4 1 Procedure for starting up a Redundant system Checking the Control System Standby System Refer to Section 4 7 Refer to Section 4 8 Refer to Section 4 9 Refer to Section 4 10 Refer to Section 4 11 Refer to Section 4 11 Refer to Section 4
414. odule of the system that is not specified in the connection target settings Ol Lu no gt no E Zz lt x a Zz Q W a 7 2 O QO 2 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 6 Writing To The Both Systems Using GX Developer 5 101 5 6 1 Writing to the CPU Module in STOP Status D REDUNDANT SYSTEM FUNCTIONS MELSEC Eseries 5 6 2 Program Change While CPU is Running Write to both systems while CPU is running i e online program change is done in the following cases e Program change in ladder mode while CPU is running e Writing a batch of files while CPU is running e T C value change while CPU is running Refer to the following manual for details on above operations L gt QCPU User s Manual Function Explanation Program Fundamentals 1 Operations When Changing Programs While CPU is running When changing the program of the control system CPU module during RUN in the backup mode the same program will be written to the standby system CPU module Even if a stop error occurs in the 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
415. of system B the Are mode settings of systems A and B of network module the same same as mode setting of system A in Redundant settings of network parameter YES YES Since the CPU model name differs between control system and standby system in redundant system use the same one Is error code 6035 NO Check to see if network cable is not YES broken since remote I O constitution of MELSECNET H multiplexed remote I O network differs between control system and standby system in the redundant system Is error code 6036 NO Hardware failure of the following modules is suspected CPU module Main base unit or extension base unit Extension cable Operate the systems sequentially from the minimum system which is the main base unit where the power supply module and the CPU module are mounted For a module which does not operate consult your local Mitsubishi representative explaining a detailed description of the problem Diagram 8 12 Flowchart for when UNIT LAY DIFF Occurs 8 24 8 1 Troubleshooting Flow 8 1 11 When UNIT LAY DIFF Occurs 8 TROUBLESHOOTING MELSEG LAY series 8 1 12 When CAN T SWITCH Occurs to Control System CPU Module due to Communication Error when Turning ON OFF Power Supply of CPU Module or Booting and Shutting Down Personal Computer in MELSECNET H Network System OVERVIEW 1 Cause of CAN T SWITCH occurrence In the redundant system where the MELSECNET H ne
416. ommunication port I Enable GX Developer TCP communication port wA o I 7 I Enable FTP communication port System B en I Enable HTTP communication port 192 0 1 2 It is necessary to set the remote password if the system switch setting during communication error is enabled in Check End Cancel Diagram 6 23 Network Parameter Setting Screen 4 System Startup Order No restrictions apply to the startup order of system A and system B when connected to the Ethernet 6 26 6 2 Redundant System Network Overview 6 2 3 Ethernet 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series 6 2 4 CC Link A redundant system can continue the CC Link control by CC Link standby master a function even when system switching occurs w ed fo When using this function set the system A as master station that controls the data link and system B as standby mas
417. on Memory Copy Using Special Memory Copy Using GX Developer VY i 2 P Relays and Special Registers Execution Conditions Memory copy executed to the standby system CPU module The following error dialog box will appear MELSOFT series GX Developer Memory copy executed in Debug Mode 424DH will be stored in SD1596 of the control system CPU Memory copy re executed during memory copy e The memory copy function is being executed I Please execute it again for a while after time lt ES 01084247 gt 4247H will be stored in SD1596 of the control system CPU During online program change or similar operation to the control system CPU module W MELSOFT application This peripheral device or another peripheral device are operating online change function A Please execute it again after it completed online change Function lt E5 010a424c gt 424CH will be stored in SD1596 of the control system CPU Memory copy target I O No SD1595 is any value other than 3D1H 4248H will be stored in SD1596 of the control system CPU Standby system power OFF Standby system CPU module reset The following error dialog box will appear E MELSOFT application Unable to communicate with PLC The Following reasons may be responsible The power supply of the standby system was turned off reset status User WDT error status PLC has a H W problem lt E5 0108a4241 gt 4241H will be stored i
418. on via the RS 232 port TRACKING CABLE ooo000 nooo oooooo nooo MEANE ojej TI I GAMILA Coll Cols eo i u ag eol teot Tracking cable REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A GOT 1000 Series GOT A900 Series CPU directly connected Remote I O module MELSECNET H Remote I O network a Serial communication module l Remote I O saton frenat VO sion Fl REDUNDANT SYSTEM FUNCTIONS 6 meae W H ep gt n 29 ax ae ae ee GOT 1000 Series GOT 1000 Series GOT A900 Series GOT A900 Series CPU directly connected Computer link connected Diagram 6 35 GOT Connection Method zZ o 6 E xO o z E Q fe ae N a fe oc E 6 3 Communication between the Both Systems CPU Module and GOTs 6 43 6 3 1 When Connecting GOTs to a MELSECNET H Remote I O network 6 REDUNDANT SYSTEM NETWORKS MELSE TA ories 2 Communication method The GOT communicates
419. one of the Following reasons Communications timeout Cable error Specified transmission speed not supported for connected PLC Monitor condition set status is read by device The project PLC and the connected PLC are different lt E5 10180840b5 Diagram 5 40 Error Dialog Box Displayed on GX Developer e During online program change If the error dialog box Diagram 5 41 appears on GX Developer wait for RUN write to complete and then change the operation mode S MELSOFT application i This peripheral device or another peripheral device are operating online change Function i Please execute it again after itcompleted online change function lt ES 01Na424c gt Diagram 5 41 Error Dialog Box Displayed on GX Developer 5 4 Operation Mode Change Function 5 61 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol Lu no gt 2 E Zz lt x a Zz Q W a 7 2 O QO 2 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS 5 62 MELSEC TA eries e During memory copy from control system to standby system If the error dialog box Diagram 5 42 appears on GX Developer wait for memory copy from the control system to the standby system to complete and then change the operation mode E MELSOFT application The memory copy Function is being executed 1 J Please execute i
420. onfirming the state of connected system and the state of the tracking cable lt E5 010a4245 gt Diagram 5 59 Error Dialog Box Displayed on GX Developer b Operations prohibited during online program change Do not perform the following operations in either control system or standby system during online program change e System power OFF e CPU module reset e 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 60 will also appear on the GX Developer that performed the PC write Ml MELSOFT application i Connected system has a communication problem Please execute it again after confirming the state of connected system and the state of the tracking cable lt E5 010a4245 gt Diagram 5 60 Error Dialog Box Displayed on GX Developer If the error dialog box Diagram 5 60 appears on GX Developer remove the condition indicated by the error dialog box and redo the PLC write c Writing a program via module mounted to extension base unit Writing a program via a module mounted to the extension base unit is disabled For details refer to the following manuals L gt GX Developer Version 8 Operating Manual L gt PX Developer Version 1 Operating Manual Programming Tool 5 100 5 6 Writing To The Both System
421. ons and host station number Applicable Appendix 6 2 Receives data in the interrupt program by the nonprocedural or BUFRCVS ee Ce ee eae ee hai N A bidirectional protocol communication SPBUSY Reads send receive status of data by dedicated instructions N A Receives data by user arbitrary transmission format in the nonprocedural INPUT y ae om fai procedural Applicable Appendix 6 3 protocol PUTE Registers user registration frame Applicable Appendix 6 4 GETE Reads user registration frame Applicable Appendix 6 5 ONDEMAND _ Sends data by the on demand function of MC protocol Applicable Appendix 6 6 Sends data as much as specified by the nonprocedural protocol OUTPUT eae 7 para p p Applicable Appendix 6 7 communication Sends data by user registration frame according to specification at user PRR registration frame specification area for sending in the nonprocedural Applicable Appendix 6 8 protocol communication Sends data as much as specified by the bidirectional protocol BIDOUT E P p Applicable Appendix 6 9 communication BIDIN Reads data received by the bidirectional protocol communication Applicable Appendix 6 10 1 Station number or operating status independent linked cannot be changed A sample program of the serial communication module where dedicated instructions are changed to the FROM TO instruction is described in the next section or later For the precautions at system switching refer to Section 7 4 App
422. ons When Changing from Separate Mode to Backup Mode MELSE TA ories MELSE fA series D REDUNDANT SYSTEM FUNCTIONS Memo NOILYHN9IHNOO g19Y9 ONIMOVYL WALSAS LNYANNAAYH To SNOILONN 4 SMYOMLAN WALSAS V dN ONILYVLS WALSAS LNVONNGSY WALSAS LNVONNGSY 404 SHNGIOOUd NILOOHSJ18NOHYL O 5 6 5 4 Operation Mode Change Function REDUNDANT SYSTEM FUNCTIONS MELSEC TA series 3 Processing After Operation Mode Change Table5 42 indicates the redundant system operations after operation mode change Program Execution Table5 42 Operations After Operation Mode Change RUN and During Continuation Error Executes the program During Stop Does not execute the program Reflects the operation result of Signal Flow Memory the control Holds system RUN LED ON OFF END Processing Executes it Consistency Check Between Systems A and B Does not execute the check Tracking Executes the function Program Change in Ladder Mode During RUN Executable Writing a Batch of Files Executable Input from Input Module on Main Inputs it Base Unit P Output to Output Module on Main Base Unit Outputs it Output from input module on Inouts it extension base unit p Output from input module on Outputs it extension base unit Automatic Refresh to Network Module on Main Base Unit CPU module network module Executes the function Automati
423. ontinue the control RUN because of system switching On Amber Separate mode Off Debug mode Indicates as shown below when the memory copy from control system to standby 7 BACKUP LED system is being executed Back up mode operation Separate mode operation Control system Standby system Control system Standby system Executing memory copy Lit Red Flashing Red Lit Amber Rete Memory copy successiully Lit Red Lit Red Lit Amber Lit Amber Indicates the system of the CPU module i e control system or standby system 8 CONTROLLED On Control system System switching is possible as the standby system is normal Debug mode Off Standby system 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 9 SYSTEM A LED normally operating as system A Flashing until the system A connector of the tracking cable is connected Off Not operating as system A i e operating as system B The SYSTEM B LED is On Indicates the system B CPU module status On Operating as system B Flashing The tracking cable has been disconnected while the CPU module is normally operating as system B 10 SYSTEM B LED Flashing until the system B connector of the tracking cable is connected Off Not operating as system B i e operating as system A The SYSTEM A LED is On Debug mode 8 TROUBLESHOOTING MELSEG LAY se
424. ontrol Standb Control Standb v Power OFF 7 y System switching will not be executed Switching System System System System Control Standb Control Standb Reseting y y System switching will not be executed System System System System System Switchin 2 9 Control Standby Control Standby n Request by Network System switching will not be executed System System System System Module System Switchin Control Standb Control Standb 7 g 1 f System switching will not be executed Manual Using GX Developer System System System System System System Switching b ue 4 4 ie ta Control Standby Control Standby BE Switching System Switching System switching will not be executed instruction System System System System Table5 31 When System Switching Cannot Be Executed Due to Network Error of Standby System System Status After System System Status Before ERE Control System ee System Switching Operation After B System Power Switching TOR Ea System Switching Method Switching Condition Condition 0 oN System A System B System A System B Stop Error Other Than Control Standby Standby Control Startup as control system Watchdog Timer Error System System System System Control Standb Standb Standb Watchdog Timer Error 4 7 E Startup as control system System System System System Control Standb Standb Control n Hardware Failure 4 4 Startup as control system Automatic System System System Syste
425. oo nooo aT I Elam Sos 0Cota Cols ola fay eST 0ESI 5 Tracking cable Systems did not switch Diagram 5 90 Operation When Error Occurs on One of the Networks eos Coss fry mm e Diagram 5 91 the processes that take place when a malfunction occurs on both networks with network module redundant group settings a Commu nication error System B Standby system oo0000 ooo OPS ar BE eol Neols Ce Tracking cable Corse ols E a gt Both modules set in the network module redundant group setting have requested a system switching LJ z Standby system System A 000000 Commu nication error Commu nication error Control system System B e OPS esika Colo B B ICANg IGANG Tracking cable Systems will switch Diagram 5 91 Operation When Error Occurs on Both Networks 5 9 Network Module Redundant Group Settings
426. oooooo000000000000000000000000000000000000000000000000000000 0 2 9 2 System Switching Time 0ocooooooooooooo0000000000000000000000000000000000000000000000000000000000000000000000000000 0 6 APPENDICES App 1 to App 51 Appendix 1 Comparison of Q4AARCPU and QNPRHCPU seseseseseceeeeeecececeeceoeceossosososssossosossssese App 1 Appendix 2 Comparison of Qn H CPU and QNPRHCPU seseseseseceeececcesecesososoeossososoosesosososesosee ADD 5 Appendix 3 Comparison of QNPHCPU and QNPRHCPU sesesesesesececeeeesecesosossoossososoossoosososososee ADD 8 Appendix 4 Sample Programs when Using CC Link eerseeeeeeeeeeeeeeeccccccceccccccccccccccescceecsscceseeeses ADD 11 Appendix 4 1 Appendix 4 2 Appendix 4 3 Appendix 4 4 Appendix 4 5 Sample Program System Configuration eeeeeeeeeeeeceecseecococcccocsecoococcsoeocsceoeceoes App 11 Sample Program Names eeeeeesesseseecoceooooocccccoosoocececocsoosocecsocoosoossseeeoosos App 11 Devices Used in Programs eeeeseeeseeeeceeceseecscocccoosccocccococecocoococossccoocoosseeoee AD 12 Parameter Settings e eeeseeeeeeeseecesocccccoececoscocccoccccosocosoccoscoccccossccossoesseesee ADD 14 Sample Program eseeeeseeeseecscoecceccccoccccocccocccocccooseccocoococcsscocccossccesccoossoss ADD 18 Appendix 5 Method for Starting up the Previous Control System ceeeeeeceececccccccccccccccccccccsccccscceees ADD 24 Appendix 6 Precautions for Using Serial Communication Module seeseeeeeeecceccecocccsecsocces
427. oper When 3 x LS gt 100ms System switching by system switching Output holding time error detection processing time 1 300 6 x LS 2 x SS I O instruction response time N Te When 100ms gt 3 x LS System switching by system switching Output holding time error detection processing time 1 400 3 x LS 2 x SS I O request from network module response time 5 7 LS Link scan time M ae ee Refer to the following manual for the link scan time calculation method aes WEZ lt 3 CC Link Master Local Module User s Manual Details SE a SS Sequence program scan time EOS 1 Use the value in Table6 6 as the error detection processing time z a Table6 6 Error Detection Processing Time 22 aye Transmission Error detection 55 speed processing time Tr 10Mbps 5ms 6 5Mbps 8ms 2 5Mbps 15ms a 625kbps 50ms gt 156 kbps 400ms g SS ae W W a a 0 Z Zg 6 95 act eC 0 Z E Q fe ae io a 2 6 2 Redundant System Network Overview 6 33 a 6 2 4 CC Link 6 REDUNDANT SYSTEM NETWORKS MELSEC TA eries 6 2 5 Serial Communication Modules Mount the serial communication module to the MELSECNET H remote I O station or extension base unit The serial communication module cannot be mounted to the main base unit where the Redundant CPU module is mounted Communication from the serial communication module to external devices can be made by MC protocol nonprocedural protocol and b
428. ops tracking PID control instruction information Stops tracking Signal flow with tracking setting Stops tracking Consistency check between System A amp B Refer to Section 6 2 1 for details e There are no items to be checked when operation mode change is made Stops operation status consistency check between System A amp B 5 4 Operation Mode Change Function D REDUNDANT SYSTEM FUNCTIONS Mi aL 3G Kel ceries OVERVIEW From Separate Mode to Backup Mode La Control system Standby system Continues execution Starts tracking Starts tracking Starts tracking CONFIGURATION SYSTEM Starts tracking Makes consistency check between System A amp B for the following items When an error is detected a self diagnostic error occurs in the standby system e File e Operation status e Main base mounting status Parameter valid drive TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol wW wn gt 2 Zz lt j zZ W ve 7 2 Q oO 2 5 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 4 Operation Mode Change Function 5 67 Control Calculating REDUNDANT SYSTEM FUNCTIONS Multiplexed Remote Master a Operations When Changing from Backup Mode to Separate Mode Back up mode Stopping Calculation Standby Mul
429. or System Switching and Output Changes at System Switching Output change when COM ZCOM instruction is used e Control system power off Since system switching is executed REDUNDANT SYSTEM FUNCTIONS No Reasons for System switching e Control system CPU module reset without tracking the output may e Control system hardware fault change at the time of system e Control system CPU module stop error switching e System switching request from network module Since system switching is done REDUNDANT SYSTEM NETWORKS 2 System switching instruction execution after tracking the output does not e System switching request from GX Developer or OPS change at system switching 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 instruction execution SM775 and special register Link refresh selection during COM instruction execution SD778 Remark Sooo eoeoc oer Refer to the following manual for details of the COM instruction and ZCOM instruction L gt QCPU Q Mode QnACPU Programming Manual Common Instructions eeseeeecevoeeeaeaeseaeoe eseeceseeeeaeeeaeeeeeaeeaoe eee eeeeaeoaes eee e ee 8 8 oO zZ o pod 03 ET ao TROUBLESHOOTING 7 1 Instructions Restricted in Use for Redundant System 7 7 PROGRA
430. ord APPENDICES Table9 4 Number of N1 to N4 Data Transferred Number of Data Transferred Words gt Number of steps for Transfer Data Time set for redundant N1 Signal flow Memor 2 g 4 parameter tracking settings each program 16 INDEX 2 Fractions are rounded up N2 SFC Information SFC program execution time 13312 13k Fixed PIDINIT Instruction Execution f 1024 1k Fixed N3 PID Control Instruction Time Information S PIDINIT Instruction 1024 1k Fixed Execution Time 4 D1 D2 D3 D4 D1 Inside Device except Index Register D2 Index Register D3 File Register Standard RAM D4 File Register SRAM Card N4 Device Data 9 1 Extension of Scan Time due to Tracking 9 5 Q PROCESSING TIME FOR REDUNDANT SYSTEMS MELSEC TA ories 9 2 System Switching Time System switching time is the time required from detection of the switching condition for the control system to the start of the new control system CPU s control Calculate the system switching time using the following expression Tsw a Tam Tre ms Tsw System Switching time Trc Reflection time for tracking data using the standby system CPU module Tam MELSECNET H CC Link PROFIBUS DP automatic refresh time Tam 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
431. otocol e Send receive function of bidirectional protocol App 30 Appendix 6 Precautions for Using Serial Communication Module APPENDICES MELSEC TA series The program example of specifying the send area head address and the send area size is shown in Diagram App 22 For the I O signal is X Y80 to X Y9F PROCESSING TIME FOR REDUNDANT SYSTEMS X9E XOF E J o 4 MOVP HOCOO DO J Sets DO to head address C00 MOVP H100 D1 Sets D1 to buffer memory length 1004 ja TOP H8 HOA2 DO K2 J Writes send area setting value Fi es a Eg Diagram App 22 Program Example The program example of specifying the receive area head address and the receive area size is shown in Diagram App 23 For the I O signal is X Y80 to X Y9F x lt Ww a z X9E X9F E or 4 MOVP HODOO DO Sets DO to head address DOOu MOVP H300 D1 Sets D1 to buffer memory length 3004 J Top H8 HOA6 DO K2 Writes receive area setting value Diagram App 23 Program Example Appendix 6 Precautions for Using Serial Communication Module App 31 APPENDICES AG Q series ELS 2 When clearing receive data without stopping the send processing in nonprocedural protocol The following shows the device and buffer memory used in the sample program of clearing receive data a Device of PLC CPU Device No X23 Table App 18 Device Used in the Program Application Receive data cle
432. ow memory Set whether the signal flow memory will be tracked or not Up to 100k words of internal devices and signal flow memory can be transferred for each tracking a Internal devices Internal devices are data of input X output Y internal relay M and others used in programs Table5 44 shows internal devices that can be tracked 1 Internal Device Default Setting Range The default tracking range is set to the internal devices as shown in Table5 45 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 5 78 5 5 Tracking Function 5 5 3 Tracking Data D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series Table5 44 Internal Devices That Can Be Tracked 3 Device Default Tracking Range Tracking Range Set by User Input XO to X1FFF X0 to X1FFF z Output YO to Y1FFF YO to Y1FFF Internal relay 1 MO to M8191 MO to M8191 Latch Relay LO to L8191 LO to L8191 Step Relay SO to S8191 S0 to 8191 Annunciator FO to F2047 7 Edge Relay VO to V2047 VO to V2047 Be Link Relay BO to B1FFF BO to B1FFF as Link Special Relay SBO to SB7FF 6 Timer Contact Points and Current TO to T2047 TO to T2047 Value wy Retentive Timer Contact Points and 9 lt Current Value Z Counter Contact
433. ower supplies simultaneously 2 Confirming the Power Supply Module POWER LED a After turning ON power supplies of the power supply modules of the main base units A and extension base units in systems A and B check that POWER LED is turned ON zg green S ao POWER LED ON green ly lt iy i POWER Z o 6 Power supply module 9 5 O Diagram 4 8 Confirm that the POWER LED of power supply module is ON Z o 2 i a 3 4 3 Module Initial Settings 4 9 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM MELSE TA ories 4 5 Confirming System A System B Identify system A and system B by checking the System A and System B LEDs of CPU modules Table4 1 Identify system A and system B by checking the SYSTEM A and SYSTEM B LEDs CPU Module LEDs System A and System B LEDs LED Name System A System B sce SYSTEMA CONTROL Sc SYSTEMB OFF N SYSTEM B Refer to the following manual for details on the CPU module LED lt gt QCPU User s Manual Hardware Design Maintenance and Inspection 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 lt QCPU User s Manual
434. owing address Table App 24 List of Buffer Memory Buffer memory address Hexadecimal decimal Setting value Stored value Switching mode 00014 MC protocol Format 1 eH oh No specification e 0007 Bidirectional protocol Es 30 rare Refer to a e OOFFy GX Developer connection For mode switching specification Transmission 0000 Set the same setting as the 914 1314 specification after setting of GX Developer 145 305 switching Refer to 8000 to 8FFFy Set the setting b the same as this area setting For switching setting Switch setting error 0 No error 203 4 515 and mode switching mode switching e Other than 0 Switch setting error confirmation error status mode switching error App 34 Appendix 6 Precautions for Using Serial Communication Module APPENDICES MELSEC TAY series a Switching mode No specification area Address 904 130p The mode No after switching 00014 to 00074 OOFFy is written to this area b15 to b0 Buffer memory address 904 1304 Default 0000 A 0001p MC protocol Format 1 00024 MC protocol Format 2 00034 MC protocol Format 3 00044 MC protocol Format 4 0005y MC protocol Format 5 0006y Nonprocedural protocol 00074 Bidirectional protocol OOF Fx GX Developer connection 1 PROCESSING TIME FOR REDUNDANT SYSTEMS 1 When specifying GX Developer connection mode in Switch setting of GX Developer specif
435. owing continuation error will occur in the e When the separate mode is changed to the standby system CPU module only OPE MODE backup mode DIFF error code 6010 e When reconnecting the tracking cable If the OPE MODE DIFF error occurs in the control and standby systems or in the standby system only adjust the operating status so that they will be consistent in the followings e CPU module RUN STOP switch position e GX Developer remote operation e Remote contact ON OFF status 5 18 5 1 Basic Concept of Redundant System 5 1 4 System Consistency Check REDUNDANT SYSTEM FUNCTIONS MELSEC TA ories c Operating Status Consistency Check Settings 1 In order that no error will be detected when the operating status is changed during normal operation uncheck Check operating status consistency 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 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 When powering on both systems simultaneously even if the backup mode redundant parameters are set not to check the Check operating status consistency has been unchecked at the backup mode settings of operation mode settings in the redundant parameter settings it will execute a consistenc
436. p 33 APPENDICES AG Q series Appendix 6 2 UINI Instruction The following shows the device and buffer memory used in the sample program for mode switching 1 Device of PLC CPU Table App 21 Device Used in the Program Device No Application Remarks X52 Mode switching request clear command ON Mode switching request clear X60 Mode switching command ON Mode switching M11 Receive processing ON Executing OFF Not executed M12 Send processing ON Executing OFF Not executed M50 Mode switching completion flag ON Mode switching completion 2 W O signal Table App 22 List of I O Signal Device to be turned ON OFF I O signal Signal name CH1 side CH2 side Xn6 XnD Mode switching O A omplete Mode switchin Switching in execution Yn2 Yn9 meee request Table App 23 List of I O Signal 1 O signal Signal name Description 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 ON Module error occurred WDT error OFF Module being normally operated 3 Buffer memory When all of the receive processing send processing and receive data clear processing are not executed write 1 to the foll
437. parameters I O Assignment settings If set to Continue system switching cannot be executed when the SP UNIT DOWN error occurs due to a network module hardware failure 5 3 The System Switching Function 5 3 3 System Switching Execution Possibility 5 REDUNDANT SYSTEM FUNCTIONS MELSEC LA series Table5 28 Operations When System Switching Cannot Be Executed Due to Standby System Power Off Resetting or Hardware Failure mj System Status After Operation After B System Power 5 System System Status Before y PS P Y 2 APE Control System eens System Switching ON OFF or unresetting the CPU Switching ieee os System Switching ee Method Switching Condition Condition module RESET L CLR switch is set System A System B System A System B to the neutral position Stop Error Other Than Control Standby Control Standby startup as ance een a Watchdog Timer Error System System System System p L 7 Control Standb Standb Standb 3 Watchdog Timer Error E 4 Startup as control system ae System System System System 2S Control Standb Control Standb Be p Hardware Failure 4 y Startup as control system Automatic System System System System System Control Standb Control Standb 2 Power OFF A 1 Startup as control system Switching System System System System A ml Control Standby Control Standby e Reseting Startup as control system O System System System System g System Switching es 5 Control Stan
438. parate mode the operation mode can be changed from the separate mode to backup mode using any GX Developer 3 Operation mode cannot be changed in the following situations e When standby system is powered off or the standby system CPU module is being reset If the error dialog box Diagram 5 35 appears on GX Developer turn the standby system on again or clear reset on the CPU module and then change the operation mode E MELSOFT application Unable to communicate with PLC The Following reasons may be responsible The power supply of the standby system was turned off reset status User WDT error status PLC has a HW problem lt E5101034241 gt Diagram 5 35 Error Dialog Box Displayed on GX Developer e When the communication with the standby system is disabled due to tracking cable disconnection If the error dialog box Diagram 5 36 appearson GX Developer check the tracking cable connection and change the operation mode E MELSOFT application s The tracking cable has a communication problem i Please execute it again after confirming the state of the tracking cable lt E5 010a4242 gt Diagram 5 36 Error Dialog Box Displayed on GX Developer e When the operation mode change request is issued to the standby system CPU module If the system switching is executed in the separate mode the operation mode change request is issued to the new control system CPU module If the error dialog box Diagram 5 37 appears on
439. pecified as the auto refresh range of CC Link to tracking transfer devices c When Redundant System is Connected to CC Link When the CC Link system master and local modules are mounted on the main base unit the redundant system cannot be started with the previous control system Appendix 5 6 2 Redundant System Network Overview 6 2 4 CC Link 6 REDUNDANT SYSTEM NETWORKS MELSEC fA series 7 Output Holding Time of Remote Station at System Switching When system switching occurs the remote station output is held until system z switching is completed a i wie ee gt 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 Table6 5 Remote Station Output Holding Time is ao Reasons for System Switching Output Holding Time Calculation Expression ms Ee Control system power off When 3 x LS gt 100ms DO Control system CPU module reset Output holding time error detection processing time 1 100 6 x LS SS I O response Control system CPU module stop error time Rae eee E od When 100ms gt 3 x LS 7 f i Uae a ea aaa eee Output holding time error detection processing time 1 200 3 x LS SS I O response a oh time 9 System switching by GX Devel
440. perations ri D 2 POINT Z z 7 5 2 2O The extension base unit cannot be connected to the main base unit where the ae Redundant CPU whose first 5 digits of serial No is 09011 or earlier is mounted aie If connected a stop error BASE LAY ERROR error code 2010 occurs When connecting the extension base unit use the Redundant CPU whose first 5 digits of serial No is 09012 or later F z O oO zZ E Q Q ae i a O 2 1 System Configuration 2 3 2 SYSTEM CONFIGURATION Mi al 26 Q ceries 2 Communication with a Host OPS PC etc a Communication via Ethernet Communication between a host OPS PC etc and redundant CPU can be performed via Ethernet Personal computer Ethernet System A Control System System B Standby System e PU Power supply module QnPRHC QJ71LP21 QJ71LP21 QJ61BT11 QJ71E71 Power supply modul QnPRHCPU QJ71LP21 QJ71LP21 QJ61BT11 QIIE Tracking cable Diagram 2 4 Connection of Redundant System to Ethernet b Ethernet Modules applicable to Redundant System Refer to Section 2 3 for Ethernet interface modules applicable to a redundant system c Ethernet Communication and Operations during 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
441. ply 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 systems simultaneously or cancel the reset Internal device tracking can be done in the separate mode Internal devices are tracked even when the operation mode is changed from the backup mode to separate mode To interrupt internal device tracking turn the tracking trigger off Section 5 5 5 When the system A and system B are powered on simultaneously or unreset RESET L CLR switch is set to the neutral position simultaneously the operation mode will change to the backup mode Make sure the tracking cable is connected to the system A and system B CPU modules before powering on the either system again in the separate mode Failure to do so may cause the TRK CABLE ERR error code 6120 stop error in the CPU module of that system 5 1 Basic Concept of Redundant System 5 1 3 Operation Mode D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 3 Debug Mode The debug mode is for performing a debug using a single system prior to redundant system operation No need to connect the tracking cable to perform the operation An error will not occur if the tracking cable is not connected In the debug mode the CPU module is fixed to system A control system Confirm that the redundant system is running in the debug mode by checking the relevant LEDs of the CPU module OVERVIEW Table
442. processing to the END instruction by executing the system switching instruction l 4 User program 6 FEND Ends the main routine program P100 S1519 Stores the value of SD412 at subroutine program 7 i Hove S412 0400 execution to D400 gt Enables system switching when the network 6 Suis S0100 o SET 41592 module in the B system starts normally r Executes the system switching instruction when the LSP CONTSH K uso04 network module in the B system starts normally Cu P101 Jumps the processing to P101 with the system switching instruction 25 con Enables communications with GX Developer or others SMISTO A 261 0412 D400 p4ot Calculates the subroutine Program which program executing time waits 10 seconds for the network D401 Kio Wor Resets the watchdog timer module startup in A the system B Continues the jumps to P100 y CJ P100 until the SD401 value becomes 10 10 seconds P101 37 RET Ends the subroutine program 39 TEND Diagram App 20 A program example EJPOINT 1 If CC Link master local modules are mounted on the main base unit system B cannot be started up as the control system Start up system A as the control system 2 By setting the abovementioned program as initial execution type program SM402 1 scan OFF after RUN SM403 1 scan ON after RUN will be usable in the system B scan execution type program after system switching 3 By enabling the signal flow memory tracking in the redundant
443. r 6 20W Product Name GX Developer PX Developer GX Simulator SW8D5C GPPW E SW1D5C FBDQ SW6D5C LLT b Applicable to extension base unit GX Developer or PX Developer applicable to the extension base unit is the one REDUNDANT SYSTEM NETWORKS whose version is shown in Table2 3 or later version Table2 3 Software Package Applicable to Extension Base Unit Version Ver 8 45X Ver 1 14Q Product Name GX Developer PX Developer SW8D5C GPPW E SW1D5C FBDQ PROGRAMMING CAUTIONS TROUBLESHOOTING 2 3 Applicable Devices and Software 2 13 2 SYSTEM CONFIGURATION MELSEC TA ories 2 4 System Configuration Cautions 2 14 1 Extension base unit 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 there are following restrictions e Use the Redundant CPUs whose first 5 digits of serial No are 09012 or later in both systems e Connect the redundant type extension base unit to the first extension stage e Only redundant power extension base unit is applicable for the second extension stage or later stage e Only one redundant type extension base unit is applicable per system e Connect IN connector IN1 and IN2 of the redundant type extension base u
444. r System Switching M Switching POTAGE Execution Timing i r Method 4 Stop error itching i hen th itchi Autonate Power off System switching is executed when the reason for system switching occurs System Reset Switching System switching request by network module System switching using GX System switching is executed at END processing of the scan where Manual Developer the reason for system switching occurred Switching System switching by system switching instruction 1 Even if the COM instruction is executed after a reason for system switching occurs system switching will not be executed by END processing Refer to the following manual for details on the COM instruction lt QCPU Q mode QnACPU Programming Manual Common Instructions 5 42 5 3 The System Switching Function 5 3 2 System Switching Execution Timing 5 REDUNDANT SYSTEM FUNCTIONS MELSEC LA series 5 3 3 System Switching Execution Possibility 1 In Backup Mode a System switching execution possibility in Backup Mode is shown in Table5 26 w lo Table5 26 System Switching Execution Capability Control System Switching Condition Z Automatic System Switching Manual System Switching 7 System T f YR System e Standby System Operating Stop Error Switching System SPN pZ Watchdog A Switching gt Q Status 1 Other Than A Hardware Power Off requested Switching Be Timer Error j Z by Sys
445. ram in the Diagram 7 11 22 r a 7 og As interrupt is disabled during END processing including tracking processing the 55 CPU will not execute the interrupt program TR 0 El Allow interrupt W 7 d Ze 86 DI Prevent interrupt T2 gt HEND 7 Diagram 7 11 Program Example That Disables Interrupts during END Processing Z o eo g Biel ET EO TROUBLESHOOTING 7 2 Cautions on Fixed scan Clocks Programs 7 13 PROGRAMMING CAUTIONS M eL SCTE cries 7 3 Precautions for Using Annunciator F in Redundant System The annunciator defaults to no tracking In the tracking setting of the Redundant parameter dialog box the annunciator can be set to within the tracking range Table7 6 provides an operation example of the control system and standby system CPU modules when the annunciator is set to within the tracking range and the annunciator F10 is turned ON in the 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 Number of annunciators turned on is SD63 No of annunciators No change stored SD64 Annunciator detection i to The annunciator No turned on is sto
446. ram is changed online the rise fall and SCJ instructions will do the following ae Cz 1 Rise instruction PLS instruction 0 P instruction SP instruction Even if the execution condition changes from off to on when online program change is complete the rise instruction will not be executed It will be executed when the execution condition is turned off and on again Z 2 Fall instruction LDF ANDF ORF MEF PLF 26 If the execution condition is off when online program change is complete the 95 fall instruction will be executed again e 3 SCJ instruction If the execution condition is on when online program change is complete a g jump to the specified pointer will be executed without waiting 1 scan 8 a 3 5 6 Writing To The Both Systems Using GX Developer 5 111 5 6 2 Program Change While CPU is Running D REDUNDANT SYSTEM FUNCTIONS MELSEC TA ories j Consistency check between both systems during online program change 1 2 3 4 5 File Consistency Check The file consistency check cannot be performed during online program change Therefore during online program change an error will not occur even if the programs of the control system and standby system CPU modules are temporarily different However if one of the followings occurs during online program change an error may occur during the file consistency check even when online program change is executed normally e Either con
447. ration Modes e System switching when a fault occurs in the control system e System switching by the system switching request issued from Backup Mode Automatic system switching the network module Manual System e System switching using GX Developer Backup Mode Switching e System switching by system switching instruction Separate Mode 5 32 5 3 The System Switching Function 5 3 1 System Switching Method D REDUNDANT SYSTEM FUNCTIONS MELSEC TE ories If system switching is performed in the backup mode the following error codes will be stored into the error history of the new control system and new standby system CPU modules In this case the ERR LED will remain off The ERR LED does not turn on or flash e New control system CONTROL EXE error code 6200 e New standby system STANDBY error code 6210 It is possible to confirm if the system switching has been executed or not in the PLC diagnostics Error log of GX Developer PLC diagnostics PLC status PLC operation status PLC operation STOP Present Error switch STOP Connective system Control system System A Backup mode PLC Module System A No error Present Error Year Month Day System B No error lt Error log Error log Clear log Error Jump Help No Error message 6200 CONTROL EXE Diagram 5 20 New Control System PLC Health Check Display Year Manth Day 2002 2 12 Eror Jump Help Trac
448. ration after system switching Continues the write operation after system switching General Data Processing Executes the request received after system switching Executes the request received at time of system switching However may develope a communication error if a system switching is executed during general 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 Does not set the value Does not process it Special Relays and Special Registers Holds the data However stores the statuses of control system and standby system after system switching in SM1515 and SM1516 Holds the data However stores the statuses of control system and standby system after system switching in SM1515 and SM1516 Sets the received tracking data in the corresponding special relay and special register Output Y Holds the output Outputs program execution results Turns OFF the output Y from modules mounted on the main base unit Holds the output Y from modules other than above Local Device Settings Sets devices according to parameter set
449. red No change number table SD79 USER LED On Off If system switching occurs when the annunciator F10 turns on in the control system CPU module whether the annunciator is on or not cannot be checked by the USER LED since the USER LED is off in the new control system CPU module System A Contro LED status USER mmm Program MO oser F10 system System B Standby system RIET LED status USER Program MO oser F10 i System A Control system Annunciator tracking System switching Standby system N system B Control system 4 Standby system el esa a ence 1 Li A H ogma e 000 EsTa ieaie Tracking cable E eo LED status USER EN Program MO 0 HASET F10 LED status USER L Program MO 0 HASET F10 Diagram 7 12 Operation of USER LED When Annunciator F10 Turns On T 14 7 3 Precautions for Using Annunciator F
450. revent this configure an external safety circuit such as fuse Build a circuit that turns on the external power supply when the PLC main module power is turned on If the external power supply is turned on first it could result in erroneous output or erroneous operation When there are communication problems with the data link refer to the corresponding data link manual for the operating status of each station Not doing so could result in erroneous output or erroneous operation When connecting a peripheral device to the CPU module or connecting a personal computer or the like to the intelligent function module to exercise control data change on the running PLC configure up an interlock circuit in the sequence program to ensure that the whole system will always operate safely Also before exercising other control program change operating status change status control on the running PLC read the manual carefully and fully confirm safety Especially for the above control on the remote PLC from an external device an immediate action may not be taken for PLC trouble due to a data communication fault In addition to configuring up the interlock circuit in the sequence program corrective and other actions to be taken as a system for the occurrence of a data communication fault should be predetermined between the external device and PLC CPU CAUTION Do not bunch the control wires or communication cables with the main circuit
451. ries 8 1 Troubleshooting Flow This section provides the troubleshooting for each possible case gt W Error Details 3 The MODE LED does not light up Section 8 1 4 To the flow for when the RUN LED does not light up Zz fe z 5 ae ae O The BACKUP LED is Be lit up solid red NO il j i n Section To the flow for when the z TOE SS TEMA LEU isi 8 1 2 BACKUP LED is lit up solid red 9 SA Q x E a M Section To the flow for when the The SYSTEM A B LED is flashing 8 1 3 SYSTEM A B LED is flashing y 2 E Saz The RUN LED does not light up Section 8 1 4 To the flow for when the RUN LED does not light up we B25 EZ 8 amp 2 a Asystem switching has occurred Section 8 1 5 To the flow for when a system switching has occurred W D rere 7 Section 8 1 6 To the flow for when a system switching could not be a The system switching could not be done en performed y PENRY T a6 55 Diagram 8 2 Troubleshooting Flow az cw W E n gt n zg ence 2O Be lu W az 0 Z o 95 cz O o Zz Q O T o wW m O iva E 8 1 Troubleshooting Flow 8 3 8 TROUBLESHOOTING 8 4 MELSEC TE eries 8 1 1 Flow for the Case where the MODE LED is not ON Diagram 8 3 is for the case where the MODE LED does not turn on when the PLC is powered on The MODE LED does not light up gt Not light or li
452. rogram Startup KEY Numerical Key Input S P SVST Request of Servo Program Startup g Axis Speed Change during Positioning and JOG 2 UDCNT1 1 phase Input Up Down Counter S P CHGV p 9 g g S operation i a Torque Control Value Change during Operation and SS UDCNT2 2 phase Input Up Down Counter S P CHGT q ra 9 one Suspension in Real Mode Current value Change of Halted Axis Synchronized TTMR Teaching Timer S P CHGA oe 7 Encoder Cam axis STMR Special Timer S P DDWR_ Write Other CPU Device Data into Host CPU ROTC Rotary Table Near Path Rotation Control S P DDRD Reads other CPU device data into the host CPU RAMP Ramp Signal oan S P GINT Request of Other CPU Interrupt Program Startup is SPD Pulse Density Measurement 2 Table App 5 Instructions Restricted for QNPRHCPU Instruction Symbol COM Selection Refresh For restrictions on COM and ZCOM refer to Section 7 1 7 ZCOM Refresh of Specified Module i Instruction Name Remark Appendix 2 Comparison of Qn H CPU and QnPRHCPU App 7 APPENDICES MELSE TA series Appendix 3 Comparison of QNPHCPU and QnPRHCPU A comparison of QnNPHCPU and QnPRHCPU is shown in Table App 6 Table App 6 Comparison of QNPHCPU and QnPRHCPU Item QnPRHCPU QnPHCPU Scan time is increased by the tracking time Periormance Scan Time Internal device 48 k word setting time i e Synchronized tracking mode 41 ms Program priority mode 21 ms lt lt First 5 digits of seri
453. rol system System System System System System Switching a Control Standby Control Standby System switching will cause system B to Request by Network System System System System become control system Module e System Switching Control Standby Control Standby p Startup as standby system Manual Using GX Developer System System System System p oan 22 System System Switching b 95 ne 4 E oe Control Standby Control Standby 22 Switching System Switching Startup as standby system wo System System System System Instruction 0 zZ E Q fe ae N W a 2 5 3 The System Switching Function 5 45 a 5 3 3 System Switching Execution Possibility D REDUNDANT SYSTEM FUNCTIONS Mi aL 20 fel ceries Table5 30 Operations When System Switching Cannot Be Executed Due to Tracking Cable Disconnection System Status After System panei Control System Before System Switching System Switching Operation After Tracking Cable erie Switching Condition Condition Disconnection System A System B System A System B Stop Error Other Than Control Standby Control Standby ate F System switching will not be executed Watchdog Timer Errors System System System System Control Standb Standb Standb Watchdog Timer Error Y y X System switching will not be executed System System System System Control Standb Control Standb r Hardware Failure A y System switching will not be executed Automatic System System System System System C
454. rom the network module the control system CPU module performs END processing Through the processing system switching is performed wW 3 After system switching is completed the new control system network module lt continues the data link g E ci Sak woe aga We 2 a D 55 ee ee ez wW 2 gt no z lt a z W a 9 X faa O z 2 W Zz PROGRAMMING CAUTIONS TROUBLESHOOTING 6 2 Redundant System Network Overview 6 17 6 2 2 MELSECNET H Remote I O network 6 REDUNDANT SYSTEM NETWORKS MELSE TA ories b Output Status during System Switching The remote I O station s output is held during system switching Example Diagram 6 15 shows the redundant system when the control system network module detects a communication error on the assumption that the control system network module is the master station and the standby system network module is the sub master station Multiplexed Remote Master Multiplexed
455. rs in the control SYSTEM cececccccccccccccccccccccccccccvccscvcsoees 5 34 T The case where the BACKUP LED of the CPU module is on red coooooooooooooooooo0o000000000000000000 B D The case where the MODE LED does not turn ON 0oco00000000000000000000000000000000000000000000000000000 8 4 The case where the control system CPU module SYSTEM A B LED is flashing coccocococooocoocooooo0 8 9 The case where the System A System B CPU module RUN LED is not on ecceceeccccccccccccccccee 9 10 Tracking CablE eccccccccococcococoocooooo000000000000000 3 Connecting a tracking Cable eeeseseeeeeeeeeceveveees 3 3 Disconnecting a tracking cable eeseseeesseeeeesese 3 4 Minimum bending radius eecccccccccccccccccccccccses 3 2 Part NAMES cecccccccccccccccccccccccccccccccccccccccccce 3 SPeCificationSecesceececceccecsecccsecsecceccccccceccecs 3 1 Tracking lata cocccccccccccccccccccccccccccccccccvcvcvccee 5 75 Tracking FUNCTION ececcccccccccccccccccccccccccccccccccee 5 74 Tracking trigger cooooooooooooooo0000000000000000000000000 5 80 Transfer tracking data during online program change enable flag cocoooooooooooooo000000000000000000 5 1 9 TRK CABLE ERR eeeeceecceccecceececceeceeseeseese 5 4 5 8 W Waiting time for online program change standby system coooooooocooooooo00000000000000000000 D 1 08 Wiring to a power supply module eesseesseeeseeeeeoe 4 5 Writing parameters and programs to CPUseesseeee 4 11 INDEX 3 PROCESSING TIME FO
456. s Appendix 6 8 PRR Instruction The following shows the device and buffer memory used in the sample program of sending data by the user registration frame of the nonprocedural protocol communication 1 Device of PLC CPU Table App 39 Device Used in the Program Device No Application Remarks X50 Transmission command ON Transmission completion X60 Transmission command pulse ON Read completion 2 W O signal Table App 40 List of I O Signal O signal A SA Signal name Description CH1 side CH2 side Transmission normal Xn0 Xn7 ON Normal completion completion Transmission abnormal Xn1 Xn8 ON Abnormal completion 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 Watchdog mer rr r ON Module error occurred X n 1 F J OFF Module being normally WDT error operated Yn0 Yn7 Transmission request ON Requesting transmission 3 Buffer memory Table App 41 List of Buffer Memory Buffer memory address Hexadecimal decimal Stored value CR LF output designation B74 183 1574 343 0 Do not send 1 Send Output head pointer designation B8 4 184 15814 344 0 No designation 1 to 100 Send from nth For user frame being transmitted Output count designati n B94 185 1594 345 0 No designation designation 1 to 100 Output n Ou
457. s Using GX Developer 5 6 1 Writing to the CPU Module in STOP Status D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series d Access to files being written The files being written by GX Developer cannot be accessed by other GX z Developer a If you access the files being written the error dialog box in Diagram 5 61 will 3 appear E MELSOFT application LD Processing is in progress From another peripheral device Please wait until the other processing is completed then execute again Z lt E5 010a4025 gt E 5 a Diagram 5 61 Error Dialog Box Displayed on GX Developer 26 Access the files 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 a dialog box in Diagram 5 62 will appear S z E MELSOFT application 6 lt i Processing is in progress from another peripheral device Please wait until the other processing is completed then execute again Y lt E5 010a4025 gt Diagram 5 62 Error Dialog Box Displayed on GX Developer ia A F 2 lt Redo the PLC write after completion of the processing performed during access woe 204 by other GX Developers Be 3 Q lt a f Write Processing in Separate Mode Tor In the separate mode GX Developer writes to the CPU module of the system that is specified in the connection target settings GX Developer will not write to the CPU m
458. s selected at the execution destination area on the Remote operation screen of GX Developer Control STOP Standby STOP system system a 6 ll fa 3 e fee af Bl El ke Fa Tracking cable GX Developer Control STOP Reset Standby STOP Reset Remote operation X system system Connection target information Connection interface COMT lt gt PLE modue rAr rare Era ag Target PLC I Stationno Host PLC type Q25PRH i a z E p O 3 PLC status RUN m ia a all fal System ype Control system Operation mode Backup mode i el e g i aj e an Operation Specify execution destination Tracking cable cpc Currently specified station Allstations Specific group Extract memory card GX Developer Reset STOP Control Standby system Reset STOP ooo oooooo
459. s situated on the side face of the CPU module MITSUBISHI MODEL Serial No first 5 digits function version Standard symbol for conformance is described wa MITSUBISHI ELECTRIC MADE IN JAPAN Diagram 2 10 Rated plate b Confirming the serial No on the system monitor Product Information List To display the system monitor select Diagnostics System Monitor of GX Developer On the system monitor the serial No and function version of the intelligent function module can also be confirmed Serial number function version Product Information List St sot type series model name Points 170 no master PLC Serial Wo ver 060510000000000 D Q Q25PRH PLC Q QJ71LP21 25 32pt 060510000000000 D None 0000 Diagram 2 11 System Monitor Product Information List Ex POINT The serial No described on the rated plate may not match with the serial No displayed on the product information of GX Developer e The serial No on the rated plate describes the management information of the product e The serial No displayed on the product information of GX Developer describes the function information of the product The function information of the product is updated when adding functions 2 3 Applicable Devices and Software 2 SYSTEM CONFIGURATION MELSEC TA series 2 Module which can be mounted to extension base unit For the module which can be mounted
460. s the number of send data SET Y80 Turns ON the send request signal X80 42 RST vso Turns OFF the send request signal if the send z completion signal is turned ON X81 44 FROMP H8 H257 D20 Ki Reads the error code and turns OFF the send request signal if the send error complete signal is turned ON Turns OFF the send request signal if the send completion signal is turned ON RST Y80 f Lt Diagram App 31 Program Example Appendix 6 Precautions for Using Serial Communication Module App 47 APPENDICES MELSEC Le series Appendix 6 9 BIDOUT Instruction The following shows the device and buffer memory used in the sample program of sending data by the bidirectional protocol communication 1 Device of PLC CPU Table App 42 Device Used in the Program Device No Application Remarks X50 Transmission command ON Transmission completion X60 Clear command ON Clear completion 2 W O signal Table App 43 List of I O Signal O signal A SA Signal name Description CH1 side CH2 side Transmission normal Xn0 Xn7 ON Normal completion completion Transmission abnormal Xn1 Xn8 ON Abnormal completion 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 i ON Module error occurred Watchdog timer error X n 1 F OFF Module b
461. s the standby master station that controls the CC Link from the previous control system standby master station to the new one when system switching occurs Network Parameter Setting Set Type station type of network parameter as follows a When mounting to the main base unit Set station type as Master station Duplex function b When mounting to the extension base unit Set station type as Master station Extension base Refer to Appendix 4 for network parameter settings System 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 performed when system B only is started up Cautions a Station No Settings Set CC Link system master and local module station Nos so that system A will be assigned to station No 0 master station and system B will be assigned to other than station No 0 standby master station b Tracking device setting Set the tracking device setting to the device where the auto refresh setting is performed in the CC Link system master local module mounted on the extension base unit Do not set the link special relay SB and link special register SW s
462. s with of the module Do not disassemble or modify the modules Doing so could cause trouble erroneous operation injury or fire Use any radio communication device such as a cellular phone or a PHS phone more than 25cm 9 85 inch away in all directions of the PLC Not doing so can cause a malfunction Completely turn off the externally supplied power used in the system before mounting or removing the module Not doing so could result in damage to the product Note that the module can be changed online while power is on in the system that uses the redundant CPU module or on the MELSECNET H remote I O station Note that there are restrictions on the modules that can be changed online while power is on and each module has its predetermined changing procedure For details refer to Section 2 4 Do not mount remove the module onto from the base unit or terminal block more than 50 times IEC61131 2 compliant after the first use of the product Failure to do so may cause to malfunction Do not drop or give an impact to the battery mounted to the module Doing so may damage the battery causing the battery fluid to leak inside the battery If the battery is dropped or given an impact dispose of it without using Before touching the module always touch grounded metal etc to discharge static electricity from human body etc Not doing so can cause the module to fail or malfunction Disposal Precautions CAUTION
463. 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 screen remote STOP is executed for the current control system CPU module nooo ooo000 tandby system Tracking cable Connection Target PLC PLC status Operation PLC Remote operation Connection target information interface COM1 lt gt PLC module RUN System type Control system STOP z C Extract memory card Stationno Host PLC type Q25PRH oo00 ooo000 Operation mode Backup mode Specify execution destination ANLAMA tandby system Cunently specified station CAIMILCANNE CAINIIGANNA All stations AHAONA ieaitiesikm Specific group i 7 Bath systems A amp B Tracking cable 5 134 5 10 5 10 GX Developer Diagram 5 97 Remote STOP Operation When Current
464. 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 8 10 8 1 Troubleshooting Flow 8 1 4 When the System A System B CPU module RUN LED is not ON 8 TROUBLESHOOTING MELSEC TA ories 1 u gt oc W gt lo Is the ERR LED ON or Has a remote STOP Perform a remote RUN to set to flashing PAUSE been done RUN status ra O T 5 a B O z no Is the RUN contact Set to RUN status by turning off PAUSE contact ON the RUN contact PAUSE contact 4 Connect GX Developer to the control E system CPU module and check for g faulty behavior using the System This is a hardware fault in the CPU 5 Monitor PLC diagnostics 4 module so please contact the nearest g Mitsubishi represenative reseller or ie branch office and explain the fault symptoms W x b Please contact the nearest Mitsubishi Caz Is there a hardware failure represenative reseller or branch office we and explain the fault symptoms AGA Es 228 a oe Clear the fault and reset with the RESET L CLR switch fi n a a 55 Please contact the nearest Mitsubishi mS Does the RUN LED light up represenative reseller or branch office Sm and explain the fault
465. sition 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 Confirm that the power supply module s POWER LED is it green and that power is being supplied properly Start standby system Diagram 8 30 Main Base Unit Replacement Procedure POINT When the standby system is powered OFF the control system CPU module develops in a STANDBY SYS DOWN error code 6300 continuation error After the replacement of the standby system CPU module is complete reset errors in the control system CPU module as necessary Refer to Section 8 2 for the error resetting method 8 42 8 3 Replacing Module in Redundant System 8 3 6 Main Base Unit Replacement Procedure 8 TROUBLESHOOTING MELSEC TA eriee 8 3 7 Procedure for Replacing Module mounted on the I O Station of Redundant System rf gt By using the online module change of GX Developer the module mounted on the w MELSECNET H remote I O network remote I O station can be replaced while the redundant system is running Following modules can be replaced by using this method I O Module 6 x e Intelligent Function Module z Analog module temperature input module temperature control module pulse Be input module ge 1
466. sly wW 12 gt no E zZ lt z Q W a 2 Zz O O 2 5 u The following stop error will occur only in the standby system CPU module only FILE x2 e When one system starts up after the other Ein Seah code e000 e When the separate mode is changed to the backup mode If the FILE DIFF occurs in the standby system execute the PLC verify by either of the methods described below to confirm the differences between the files of both system correct the problem file and perform write to PLC again e After reading the system A programs and parameters using GX Developer or PX Developer compare them with the System B programs and parameters e Verify the GX Developer and PX Developer programs and parameters saved in the offline environment with the those written to both system CPU modules REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS 1 Ifthe memory capacities of the area for online change of multiple blocks are different in both systems carry out the following operations Using memory copy from control system to standby system function copy the program memory contents of the control system to the standby system Format program memories of both system CPU modules The memory capacities of the area for online change of multiple blocks will be the same 2 Ifa stop error occurs in the standby CPU module the STANDBY SYS DOWN error code 6300 continuation error will occur in the
467. ssary space is available in a memory card SRAM card or ATA card a batch of files can be written into the card during RUN OVERVIEW CONFIGURATION SYSTEM b Memory used for file batch online program change The file batch online program change uses the same memory in the control system and standby system CPU modules If different memories are available in the control system and standby system CPU modules the file batch online program change is not executed TRACKING CABLE Table5 57 Memory Available for Control System and Standby System CPU Modules and File Batch Online Program Change Execution Possibility Memory available for control Memory available for standby system O x Memory card x O system Program memory REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A When the file batch online program change could not be executed the error dialog box in Diagram 5 68 appears Ol E MELSOFT application i Exceeds specified memory range Check and retry Y W 2 gt 2 E zZ a lt E5 0180204a gt zZ za W a 2 Zz O oO Z u Diagram 5 68 Error Dialog Box Displayed on GX Developer c Operations disabled during online program change Do not perform the following operation during online program change REDUNDANT SYSTEM N e System power OFF e CPU module reset E Zz e Tracking cable connection or disconnection Executing any of the above operations may corrupt the
468. stallation screw if installed in a location exposed to strong vibration or impact In such cases tighten the module installation screw within the following range Module fixing screw M3x12 screw Tightening torque range 36 48 Necm 4 4 4 1 Mounting Modules PROCEDURE FOR STARTING UP A REDUNDANT SAE MELSEC fAfssries 4 2 Wiring z This section explains wiring to the power supply module necessary for starting up a redundant system connection of the Q6BAT battery connectors tracking cable z connection Install the wiring to a network module by referring to the corresponding manual as the wiring method differs according to model z e Install the wiring to an I O module by referring to the following manual as the wiring E method differs according to the model Eg T I O Module Type Building Block User s Manual 8 1 Wiring to a Power Supply Module Connect a power cable and ground cable to the power supply module on a main base El unit by referring to the wiring example shown in Diagram 4 3 i Z pui LineB 100V 200VAC Aac alle f o Main base unit Q35B Main base unit Q35B 4
469. standby system and the MELSENET H module operate normally by the special register A sample program to cancel an error by the error cancel command M100 at the time of CAN T SWITCH occurrence is shown in Diagram 8 13 In this sample program when CAN T SWITCH occurs to the control system CPU module due to system switching request from the network module an error CAN T SWITCH can be cancelled by turning ON the error cancel command M100 after checking that the standby system CPU module and the MELSECNET H module operate normally However when systems cannot be switched by other than system switching request CAN T SWITCH cannot be cancelled in this sample program Program example An error CAN T SWITCH No 6220 is cancelled when the system cannot be switched normally sD1590 H KO p1690 ove K6220 p50 SD158940 system error information SD1600 and system switching request module No from CSM50 the host system or other system network module SD1590 and SD1690 are all normal in the system 8 26 3 END E switching request by the network module SD1588 3 Diagram 8 13 Sample Program to Cancel an Error CAN T SWITCH When executing the error cancel command automatically change error cancel command M100 in Diagram 8 13 to be always ON SM400 Programming of MELSECNET H The MELSECNET H network detects a temporary communication error depending on conditions such as power supply ON OFF or cable
470. stination y VES fo HEIN pP Target system Connection test system 6 Pernai E E o l E Not specified PLC type C24 NET IO H NET N CC Link _Ethemet Heke 5 System image a Z9 BREE amp 28 5s C24 NET 10 H NET II CC Link Ethernet a Ti Accessing host station a2 Diagram 6 1 Connection Setup Screen Z no E O g Q 2 rt a 2 6 1 Communication with GX Developer and PX Developer 6 1 z 6 1 1 Communication Methods with GX Developer 6 REDUNDANT SYSTEM NETWORKS System Specification Not specified Default CTO cries Table6 1 GX Developer System Specification and Communication Paths Select this option to communicate with only the CPU module connected to GX Developer System not specified default Communication Path cI System A Control E e E Sys aa Control System Select this option to communicate with the control system CPU module using GX Developer If system switching occurs communication is done with the new control system CPU module If the CPU module connected to GX Developer is the control system communication is done with that CPU module If the CPU module connected to GX Developer is the standby system communication is done with the other system the control system via the tracking cable GX Developer System A C eat
471. supply module supplies power to the modules mounted on the same base unit Redundant Power supply module 7 Control Standby sz system system 2 i l T T re s gl a nO B 2 i a Tracking cable l 3 Oo z xe Q GX Developer Replace the redundant power supply module 1 Procedure for Replacing Redundant Power Supply Modules i The procedure for replacing redundant power supply modules is shown in the g A Diagram 8 21 rto rob ass aes zea J one Confirming the Replacement Target Power Supply Module Identify the faulty power supply module using the System Monitor of GX Developer z Power OFF the Target Power Supply Module 2 209 36 Ze Removing the Wiring az Disconnect the power supply cable from the target power supply module aia l Replacing the Power Supply Module z 1 Remove the power supply module from the main base unit D 2 Mount the replacement power supply module to the main base unit Refer to the QCPU User s Manual Hardware Design Maintenance and Inspection 22 regarding disconnecting and attaching power supply modules 26 0 Z no z 95 Confirming the POWER LED of the Power Supply Module ES Confirm that the power supply module s POWER LED is ON and that power is being supplied properly Completed Diagram 8 21 Redundant Power Supply Replacement Procedure o Zz Q O T o wW a O iva E 8 3 Replacing Module in Redundant System 8 35 8 3
472. switching E E This function switches the operation mode between the separate mode and Section 5 4 backup mode This function transfers the operation control data to the standby system to ensure continuous system operation when a control system failure or fault Tracking Function occurs Section 5 5 Control can be continued with the same data even if a control system failure or fault occurs and the systems switching occurs This function transfers the data such as programs including those written Online Program Change for online and parameters written to the control system CPU from the standby Section 5 6 Redundancy system This function copies program memory contents from the control system to the standby system Memory Copy from Control When exchanging the standby system CPU module use of this function can Section 5 7 System to Standby System make the control system and standby system program memories consistent This function can be executed by using GX Developer or by using the special relay and special register e Function to replace I O module mounted on the main base unit where the Redundant CPU is mounted while power supply is ON Not applicable when the extension base unit is connected e Function to replace the I O module and intelligent function module function Online Module change version C mounted on the extension base unit while power supply is ON Section 5 8 Hot swapping e Function to replace the I O module an
473. symptoms W E n d Completed A g ZO 35 Diagram 8 6 Flow for the Case where the System A System B CPU Module RUN LED is not ON Di 0 Z 2 no E O o Zz Q O T o wW a O iva E 8 1 Troubleshooting Flow 8 11 8 1 4 When the System A System B CPU module RUN LED is not ON 8 TROUBLESHOOTING 8 12 MELSEC TA eries 8 1 5 When System Switching has Occurred The following flow Diagram 8 7 is for the case where system switching has occurred while the redundant system is running Asystem switching has occurred Connect GX Developer to the control system CPU module and check the error log using the System Monitor PLC diagnostics Does the control system CPU module s error log contain CONTROL EXE error code 6200 A system switching has not occurred Monitor the system switching cause using GX Developer PLC diagnostic error log and reviewing details for CONTROL EXE error code 6200 Turn ON the standby system power Set the CPU module s RESET L CLR switch to the neutral position 8 1 Troubleshooting Flow 8 1 5 When System Switching has Occurred 8 TROUBLESHOOTING MELSEG LAY series 1 if oc W gt fe Connect GX Developer to the standby system CPU module and check for faulty behavior using the 2 System Monitor PLC 2 diagnost
474. system is ae completed until the online program change to the standby system starts falls outside ae the SD1710 setting range this function judges it as a communication error and abnormally completes the online program change SD1710 defaults to 90 seconds and can be set within the range 90 to 3600 seconds g S S o 2 ui a 3 5 6 Writing To The Both Systems Using GX Developer 5 107 5 6 2 Program Change While CPU is Running D REDUNDANT SYSTEM FUNCTIONS MELSEC TA ories 6 Special Relays And Special Registers For Online Program Change a Special Relays For Online Program change Special relays for online program change are shownin Table5 55 Table5 55 Special Relays For Online Program change Number Name Manual system switching disable enable setting during online program change redundant tracking SM1709 1 Explanation Turning this relay from OFF to ON enables manual system switching during online program change redundant tracking After the manual system switching disable status is canceled the system automatically turns off SM1709 System switching due to any of the following conditions is executed even during online program change redundant tracking regardless of the status of this relay e Power off reset hardware failure CPU stop error In either of the following statuses the system switching disable status can also be canceled by this relay e Multiple block online program change redundant
475. system off and back on 7 System A Control System System B Standby System REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A a Start in Hot start mode Ol CAMEO o Tracking cable D100 D101 1234 2345 Lu 12 gt no E Zz lt x a Zz Q W a 7 2 O QO 2 u Diagram 5 19 Hot Start Mode Operation REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 1 Basic Concept of Redundant System 5 29 5 1 6 Start Mode D REDUNDANT SYSTEM FUNCTIONS MELSEC LA series 3 Differences Between Initial Start Mode and Hot start Mode Table5 20 shows the differences between Initial start mode and Hot start Mode Table5 20 Differences Between Initial Start Mode and Hot start Mode Initial Start Mode Hot Start Mode All Other Than Index Register Not held in power OFF Cleared Held and Step Relay Held in power OFF Held Device Index Register and Step Relay Cleared Memory Special Relay and Special Register Initial value is set Initial Device Value Setting Range Initial value is set Local Device Cleared File Register Held Initial Execution Type Program Executed only one
476. t 2 Even within the gratis warranty term repairs shall be charged for in the following cases 1 Failure occurring from inappropriate storage or handling carelessness or negligence by the user Failure caused by the user s hardware or software design 2 Failure caused by unapproved modifications etc to the product by the user 3 When the Mitsubishi product is assembled into a user s device Failure that could have 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 fires or abnormal voltages and Failure caused by force majeure such as earthquakes lightning wind and water damage 6 Failure caused by reasons unpredictable by scientific technology standards at time of shipment from Mitsubishi 7 Any other failure found not to be the responsibility of Mitsubishi or that admitted not to be so by the user 2 Onerous repair term after discontinuation of production 1 Mitsubishi shall accept onerous product repairs for seven 7 years after production of the product is discontinued Discontinuation of production shall be notified with Mitsubishi Technical Bulletins etc 2 Product supply
477. t App 51 APPENDICES MELSEC LA series Memo App 52 Appendix 7 Restrictions on Communication via Module Mounted to Extension Base Unit INDEX A Applicable CIAVICES ceccccccccccccccccccccccccvcccccccccs D Applicable Software eecccccccccccccccccccccccccccccccece D Applicable software packages sereseeseseseeseseseeee 2 13 Asynchronized tracking Mode seeeeeseceeceeeeeeecvees 5 96 Automatic system switching ecccccccccccscccccscscccee D 34 System switching requested by the network MOIUIE ececccecccccccccccccccccccccccccccccccccccscscees 535 System switching when a fault occurs in the control system coocooooooooooooo00000000000000000000000 534 Automatically transferred special registers e sees 5 84 Automatically transferred special relays s seesee 9 5 83 B Backup MOE ecccccccccccccccccccccccccccccccvcccccvccceee H Q Basic concept of redundant systemeseeseeseceecceees 5 1 Basic system configuration consistency check 5 20 Both systems operations after system switching coooooooooooooooooooooo00000000000000000000000000 51 C Canceling the debug MOE eccccccccccccccccccccccccee 5 1 3 Card removal setting enable flag SM609 essese 5 23 Cautions Cautions when connecting a tracking cable sess 3 2 Handling CAUTIONSecececccccccccccccccccccccccccscccccs 4A Cautions when connecting a tracking cable eesesee 3 2 Changing from separate mode to backup mode COC COOH OOOO OOOO OOOO OOOO OOO OOOO OOO OO OOO OOOOOOO
478. t again fora while after time lt ES 010a9247 gt Diagram 5 42 Error Dialog Box Displayed on GX Developer e When a stop error occurs in the control system CPU module the RUN LED flashing If the error dialog box Diagram 5 43 appears on GX Developer cancel the control system CPU error and change the operation mode E MELSOFT application Operation mode is being changed from backup to separates Please change RUN LED blink PLC from STOP status to RUN status After it Please execute the change of Operation mode again lt ES 010a4258 gt Diagram 5 43 Error Dialog Box Displayed on GX Developer 5 4 Operation Mode Change Function MELSE fA series D REDUNDANT SYSTEM FUNCTIONS Memo NOILYHN9IHNOO g19Y9 ONIMOVYL WALSAS LNYANNAAYH To SNOILONN 4 SMYOMLAN WALSAS V dN ONILYVLS WALSAS LNVONNGSY WALSAS LNVONNGSY 404 SHNGIOOUd SNILOOHS3S1ENOwL isp 5 6 5 4 Operation Mode Change Function D REDUNDANT SYSTEM FUNCTIONS Program execution MELSEC LA series 2 Operations When Changing Operation Mode The CPU module operations after operation mode change and the input output processing to the remote station are shown in Table5 41 Refer to Table5 41 for operations during operation in the corresponding operation mode Function Operation Table5 41 Operations When Changing Operation Mode Operation status RUN From Backup Mode to Separate Mode 0x0 I system Con
479. t possible ooo ooooo0 E3 me Col eolz Col eoT s Tracking cable CC Link J O Remote I O station station No 2 Diagram 6 27 Operation at System Switching due to Communication Error of Network other than CC Link 6 2 Redundant System Network Overview 6 2 4 CC Link 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series c When System Switching is Manually Carried Out When system switching is manually carried out the new control system takes a over the control of the redundant system 2 i jam However the new standby system master station does not switch to the standby z master station as it can communicate with remote stations Also 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 s 5 E Make sure to switch the data link control from the standby
480. t solid red QCPU User s Manual Hardware Design Maintenance and Inspection The power supply module s POWER LED Is current being supplied to the power supply module Is the power supply module cabling normal Connect GX Developer to the CPU module Is communication with G Developer possible NO Check the wiring and turn on the power NO YES Does the MODE LED light up Perform a PLC diagnostic and troubleshooting based on the diagnostic results Is the CPU module s RESET L CLR Switch set to the neutral position After resetting using the RESET L CLR switch return the switch to the neutral position RESET Position Neutral position lt 4 Replace the power supply module and confirm the POWER LED is lit Does the MODE LED light up Does the MODE LED light up The following modules may be experiencing YES Power supply module hardware fault hardware errors y 1 CPU module Completed 2 Basic base module 3 Network Module Confirm operation of a minimum system of the basic base module with a power supply module and CPU module installed and slowly build up from this For modules that are not functioning please contact the nearest Mitsubishi represenative reseller or branch office and explain the fault symptoms Diagram 8 3 Flow for the Case where
481. tability Remarks m Not connectable since the stop error EXTEND BASE ERR error lt Bus connection x 7 Oo code 2010 occurs to the CPU module z CPU direct g connection O E 3 Not connectable since the serial communication module cannot be Computer link Main base unit where neon x mounted to the main base unit where the Redundant CPU is Redundant CPU is mounted 7 mounted Ethernet connection O 2 lt r55 MELSECNET H PLC Ags to PLC network O Sir 5 MELSECNET 10 PLC aoe to PLC network O CC Link connection O Bus connection x Not connectable No error occurs to the CPU module a n Computer link A serial communication cannot be mounted to the main base unit on a connection O which a redundant CPU is mounted gO Ethernet connection O 55 Extension base unit MELSECNET H PLC Not connectable since the MELSECNET H module cannot be Er to PLC network i mounted to the extension base unit MELSECNET 10 PLC Not connectable since the MELSECNET H module cannot be 6 to PLC network a mounted to the extension base unit a CC Link connection O L n Bus Connection x z g ja i 20 MELSECNET H remote Direct O 5z O station onnecton 2 Computer Link Connection O Bus Connection x CPU Direct i Gi MELSECNET 10 remote e A x Not connectable since the MELSECNET 10 is not compatible with Z I O station onnection the Redundant CPU Zo Computer Link 6 A x GE Connection ee O Applicable x N A 1 EXTEND BASE ERR error code 2012 occurs
482. tandby system CPU the error dialog box in Diagram 5 94 will appear on GX Developer In this case change the connection target of GX Developer to the control system REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A B MELSOFT application W MELSOFT application iJ Ol ame 4 This Function cannok execute with control system of transfer setting ot standby system of transfer setting The executed Function is nok supported in standby system Please check the manual and other documentation 13 Please change transfer setting and ene it again 2 X lt E5 010a42402 lt ES10IDa4243 gt Diagram 5 94 Error Dialog Box That Appears When Forced ON OFF Cancel Is Executed in Standby System Lu no gt no E Zz lt a Zz Q W a 7 2 O QO 2 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 10 Redundant CPU Functions Restricted in Redundant System 5 129 5 10 1 Enforced ON OFF of external I O D REDUNDANT SYSTEM FUNCTIONS MELSEC TA ories 2 Tracking of Registered Forced ON OFF Information from Control System to Standby System The forced ON OFF information registered in the control system CPU module is tracked to the standby system CPU module Track the registered forced ON OFF information from the control system CPU module to the standby system CPU module in the backup mode or separate mode Hence if system switching occurs the external I
483. tation including standby system CPU module or booting and shutting down the personal computer where the MELSECNET H communication board is mounted the 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 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 SWITCH refer to Section 8 1 12 For details of the MELSECNET H network system refer to the following manual L7 Q Corresponding MELSECNET H Network System Reference Manual PLC to PLC network 6 14 6 2 Redundant System Network Overview 6 2 1 MELSECNET H PLC to PLC network 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series 6 2 2 MELSECNET H Remote I O network A redundant system uses a multiplexed remote I O system of MELSECNET H remote I O network to continue the control of remote I O stations even when system switching occurs The multiplexed remote I O network system consists of multiplexed remote master station that controls remote I O stations and multiplexed remote sub master stations that is for backup of multiplexed remote master station In a redundant system make sure to set system A as the multiplexed
484. tation 5 jag Control system Standby system a 3 f gt a B i B g GZ 3 BHA i 3 eel Tracking cable z CC Link S GOT 1000 Series GOT 1000 Series GOT A900 Series AJ65BT G4 S3 GOT A900 Series 5 TN 3 E OL g GOT 1000 Series a ica GOT A900 Seri I Remote device Intelligent device 2 station station a amp 2a Diagram 6 36 System When Connecting GOTs to CC Link azo B amp R oo 1 GOT connection methods The connection method for connecting GOTs to the CC Link is referred to as CC Link connection fi In this method mount a CC Link communication unit GOT dedicated product to a gt GOT and then connect it to the CC Link 22 25 icati a5 2 Communication method oc 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 base unit the GOT always monitors the control system For details refer to the following manual L gt GT Designer2 Version2 Screen Design Manual oe Lu 2 gt no Zz lt x Q Zz Q W a n X faa O z 2 W Zz PROGRAMMING CAUTIONS TROUBLESHOOTING 6 3 Communication between the Both Systems CPU Module and GOTs 6 45 6 3 2 When Connecting GOTs to CC Link 6 REDUNDANT SYSTEM NETWORKS
485. tatus where a continuation error has occurred Stop Error The CPU module has stopped as a stop error has occurred 6 lt L Power Off The system power is OFF 25 Resetting The CPU module is being reset Eg Q At network fault A fault has been detected by at least one module of standby system network modules DO detection MELSECNET H network module Ethernet interface module PROFIBUS DP master module Preparing for i Rt i i TA The communication is not made between the control system and standby system via tracking cable wW System lt Switching The system switching has not been completed as a data error occurred due to noise etc in the 2 Request communication between the control system and standby system during system switching processing Z Timeout Executing oo f uae System switching cannot be executed since the control system or standby system is executing system z w switching due to the previous system switching condition fe Switching Gas a 2 Watchdog timer error corresponds to WDT ERROR error code 5000 OR 5001 zok 22 Sta ZDE Table5 35 Operations When System Switching Cannot Be Executed Due to Operation mode i e Separate Mode 5 System Status After System Bethe Control System Before System Switching System Switching Operation After Changing From nein Switching Condition Condition Separate Mode to Backup Mode System A System B System A System B E a Stop Error
486. tch station No of systems A and B to monitor when system switching occurs For details refer to the following manual lt gt GOT A900 Series User s Manual GT Works2 Version2 GT Designer2 Version2 compatible Connection System Manual 6 3 Communication between the Both Systems CPU Module and GOTs 6 3 3 Communication when the GOT is Connected to MELSECNET H or MELSECNET 10 PLC to PLC 6 REDUNDANT SYSTEM NETWORKS MELSEC feries 6 3 4 When Connecting GOTs to a Ethernet The GOT is connected to Ethernet mounted on the main base unit or Ethernet mounted on a the extension base unit w O 1 GOT Connection Methods Connect GOTs to a Ethernet via Ethernet connection Zz 6 GOT 1000 series 5 GOT A900 series 25 Ethernet connection ng nZ Ethernet GS Syetem A Station Syetem B Station Control system No 1 Standby system No 2 daaa A o alale iy El eL al amp JHE S Tracking cable z x jam Diagram 6 38 GOT Connection Type when Mounting to Main Base Unit fe Syetem A Control system Syetem B Standby system L a g a g Fra Q 2 mE 8 amp 2 Tbe Tracking cable pA R W D d ZO 56 Ethernet 55 15 oe TE GOT 1000 series Ethernet connection ez Diagram 6 39 GOT Connection Type when Mounting to Extension Base Unit Lu 2 gt 2
487. telli Intelli Intelli None gent gent gent Diagnostics Gi iacaa ta ail Module s Detailed Information Z Base Information 2 7 Product Inf List A Status E raea aeti o O EE Module system eror Module error Module waming Detailed inf of power supply 3 5 E Module change EE Eror in connected system Stop monitor Close T g Diagram 1 12 System Monitor of GX Developer oO me Q fe ae N W a re E 1 2 Features 1 241 1 OVERVIEW MELSEC TAY cores 11 Compact Redundant System The space of control panel can be saved as Q series modules other than the CPU module redundant power supply module and tracking cable are 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 Control system Standby system Tracking cable Diagram 1 13 Horizontal Arrangement of Control System and Standby System Control system L Tracking cable Diagram 1 14 Vertical Arrangement of Control System and Standby System 1 22 1 2 Features 2 SYSTEM CONFIGURATION MELSEC TA ories CHAPTER2 SYSTEM CONFIGURATION This chapter explains the redundant system configuration OVERVIEW 2 1 System Configuration NO An example of redundant system configuration is illustrated in Diagram 2 1 OPS 2 O E gt o iE Z
488. tem EL ale Lore Failure Reset by the using GX Switchin Timer Error Network Developer g Instruction Module i Normal O O O O O O O 2 Continuation ERROR O O O O O O O g xe Power OFF fue Resetting x Oo On x x x x a Hardware Failure Watchdog Timer Error 2 2 x O O O x x x Stop Error Other Than g o x x x Let Watchdog Timer Error O O O O wo E At network fault detection O O O O x x x a z Q Memory Copy from Control Q lt a ane System to Standby System O O O O i During Online Program Change O O O O x x x 5 Operating Status Inconsistency O O O O x x x T Tracking Cable Disconnection x o o t x x x x gt Preparing for Tracking x O O O x x x A 2 5 GO System Switching Request ZE Timeout O O O 5 i i D 5 Executing System Switching O O O O O x x System switching enabled x System switching disabled 1 Standby System Operating Status is displayed in Table5 27 2 When the reasons for system switching failure such as standby system power off being reset a standby system stop error tracking cable disconnection are removed the system switching may z9 occur lt _ gt Table5 28 to Table5 32 z S 3 Watchdog timer error corresponds to the WDT ERROR error code 5000 OR 5001 p m 4 The control system switches to the standby system but the standby system status does not change 0 Z Zg 6 95 act O 0 zZ E Q fe ae ia a oc E 5 3 The System Switching Function 5 43 5 3 3
489. tem Using GX Developer The following provides the procedure for executing memory copy function using GX Developer and the relevant operations a Procedure 1 Connect the control system and standby system CPU modules with a tracking cable and power on the standby system Control system CPU module Standby system CPU module ON red Q12PRHCPU Q12PRHCPU MODE BACKUP MODE BACKUP m RUN CONTROL RUN CONTROL ERR systema J ERR J SYSTEMA USER SYSTEMB ON red USER SYSTEMB BAT BAT BOOT BOOT ON red Flashing red Diagram 5 77 LED Indications When Tracking Cable Is Connected 2 Ifthe 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 SM1515 Control Status ON SM1516 Standby status OFF 5 4116 5 7 Memory Copy From Control System To Standby System D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 3 Select Memory copy on the Redundant operation screen of the Online dialog box on GX Developer and click the Execute button
490. tenance 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 first extension stage 2 The intelligent function module other than the analog module temperature input module temperature regulating module and pulse input module are not compatible with online module change hot swapping using GX Developer For the intelligent function module which is not compatible with online module change hot swapping using GX Developer turn OFF power supply of the power supply module before replacing modules 8 3 Replacing Module in Redundant System 8 3 8 Replacement of Modules Mounted to Extension Base Unit 8 TROUBLESHOOTING MELSEC Eseries 8 3 9 Tracking Cable Replacement 1 Tracking Cable Replacement a The tacking cable cannot be replaced while both systems are running w 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 ru
491. ter Ei Number of Tracking Device Ranges outside of Index Register K5 4x103 E2 Number of Tracking Device Ranges for Index Register K6 5x103 Number of Tracking Device Ranges for Standard RAM File E3 K7 5x 10 Register Number of Tracking Device Ranges for SRAM Card File a i k8 5x 10 Register Ei Number of Blocks not Including File Register K9 1x103 F2 Number of Blocks Including Standard RAM File Register K10 25x103 F3 Number of Blocks Including SRAM Card File Register K11 2 2 The value of K11 differs depending on QNPRHCPU Serial No QnPRHCPU whose first degits of serial No is 06081 or before 120 3 x G 3 x 108 QnPRHCPU whose first degits of serial No is 06082 or later 120 x 108 3 Gis the number of clusters of the specified file register Calculate it using the following expression G file register capacity size of one cluster Round up the fractional portion of G calculated by the above expression Use the following value as the size of one cluster Q2MEM 1MBS 256 words 512 bytes Q2MEM 2MBS 512 words 1024 bytes 9 8 9 2 System Switching Time APPENDICES MELSEC LA cries APPENDICES Appendix 1 Comparison of Q4ARCPU and QnPRHCPU PROCESSING TIME FOR REDUNDANT SYSTEMS A comparison of Q4ARCPU and QnPRHCPU redundant systems is shown in Table App 1 Table App 1 Comparison of Q4ARCPU and QnPRHCPU Redundant Systems Item QnPRHCPU Redundant System Q4ARCPU Redundant System I
492. ter Screen 2 Write the redundant parameter in which Do not start with Debug mode is set r E 0 into the CPU module and power on the system again or set the RESET L CLR a s ses O switch of the CPU module to reset switch neutral position Then the system i will start up in the operation mode other than debug mode A 3 oc E 5 1 Basic Concept of Redundant System 5 13 5 1 3 Operation Mode D REDUNDANT SYSTEM FUNCTIONS MELSEC TA ories b Precautions 1 X The following redundant system functions cannot be executed in the debug mode as the systems do not operate as a redundant system even when they are connected with the tracking cable e System switching including manual system switching Memory copy from control system to standby system e Tracking The debug mode cannot be changed to the backup mode or separate mode with GX Developer as it is set by the redundant parameter Cancel the debug mode if the dialog box Diagram 5 10 appears on GX Developer MELSOFT series GX Developer J Cannot execute this function when the PLC status is debug mode Diagram 5 10 Error Dialog Box Displayed on GX Developer Change the redundant parameter to cancel the debug mode When mounting the MELSECNET H remote master station on the main base unit set the station No to 0 master station If the station No is set to other than 0 the LINK PARA ERROR error code 3101 stop error
493. ter station for backup of master station Refer to the following manual for CC Link standby master function L gt CC Link System Master Local Module User s Manual Z E jag Master Station Standby Station 3 Station No 0 Station No 1 i 26 no System A Control System System B Standby System E l Die H E 3 Tracking cable S 5 x fue E Remote I O station station No 2 a c b E woe 204 i i mE Master station operation standby oe St 2 master station operation Station No 0 Station No 1 ARE System A System B Control System Standby System gt f g faa E g RI g 1 5 a fe Communication a lt lay By Uy not possible gt 3 a o Zz 5 E a zo AQ Tracking cable 55 ee u3 u ez Remote 1 O station station No 2 Diagram 6 24 CC Link Operation at System Switching Lu 2 gt no Zz lt x a Zz Q W a n X faa O Ss 2 W Zz POINT 1 Auto refresh can be made when mounting the CC Link system master local module to the extension base unit Set the tracking device setting to the o device where the auto refresh is performed M When using the auto refresh set Refresh settings of the network parameter Z 2 Set the tracking device setting to the device where the auto refresh is set ga Z o 2 i a 3 E 6 2 Redundant System Network Overview 6 27 6 2 4 CC Link 6 REDUNDANT SYSTEM NETWORKS MELSE TA ories
494. the following procedure prior to use 3 a Confirming Battery Installation Status Open the CPU module bottom cover and confirm that the battery is installed properly 6 b Connecting the Battery Connectors o Align the connector mounted in the case with battery connector pin and insert it G Connector Battery Connector Stay TRACKING CABLE A CPU module Diagram 4 4 Connecting the Case Connector and Battery Connector Pin Refer to the following manual for installation of Q7BAT batteries and SRAM card batteries applicable to CPU modules W n gt n f Zz lt x 5 z a W oc 5 X lt we Of TE aw K7 QCPU User s Manual Hardware Design Maintenance and Inspection REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 4 2 Wiring 4 i7 PROCEDURE FOR STARTING UP A REDUNDANT SELL Mi aL 26 FY conics 3 Connecting a Tracking Cable Connect a tracking cable to CPU module tracking connectors according to the following procedure a Confirming System A System B Connectors Confirm each connector of system A system B b Connecting a Tracking Cable Connector Align the tracking cable connector with the CPU module TRACKING connector and then connect them a Redundant CPU Diagram 4 5 Connecting a Tracking Cable Connector Make sure to tighten the tracking cable connector fixing screws after conn
495. them by quoting the details in the tables below Related Manuals Manual Number Model Code Manual Name QCPU User s Manual Hardware Design Maintenance and Inspection This manual provides the specifications of the CPU modules power supply modules base units extension SH 080483ENG cables memory cards and others 13JR73 Sold separately QCPU User s Manual Function Explanation Program Fundamentals This manual explains the functions programming methods devices necessary to create programs with the SH 080484ENG QCPU 13JR74 Sold separately QCPU Q Mode QnACPU Programming Manual Common Instructions SH 080039 This manual describes how to use the sequence instructions and application instructions 13JF58 Sold separately QCPU Q Mode QnACPU Programming Manual PID Control Instructions SH 080040 This manual describes the dedicated instructions used to exercise PID control 13JF59 Sold separately QCPU Q Mode Programming Manual SFC This manual explains the system configuration performance specifications functions programming debugging SH 080041 error codes and others of MELSAP3 13JF60 Sold separately QCPU Q Mode QnACPU Programming Manual MELSAP L This manual describes the programming methods specifications functions and so on that are necessary to SH 080076 create the MELSAP L type SFC program 13JF61 Sold separately QnPHCPU QnPRHCPU Programming Manual Process Control Instructions This manual
496. time during STOP RUN Program Interrupt Permitted Not Permitted Set to not permit interrupt Execution 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 Standby Based on the PLC parameter settings File Register Settings Based on the PLC parameter settings Comment File Settings Based on the PLC parameter settings SFC Program Startup Mode Based on the PLC parameter settings Boot from Memory Card Standard ROM Based on the PLC parameter settings Intelligent Module Parameter Initial Settings The intelligent module parameters are reflected Clear device data by latch clear 5 30 5 1 Basic Concept of Redundant System 5 1 6 Start Mode D REDUNDANT SYSTEM FUNCTIONS AG Q series 5 2 FUNCTION LIST The redundant system functions are listed in Table5 21 Please refer to the following manual for functions other than the redundant system functions C7 QCPU User s Manual Function Explanation Program Fundamentals Table5 21 Function List Item Description Referecne System Switching Function This function switches the control system and the standby system It changes Switching between the the control system to the standby system and the standby system to the Sedins 3 Control System and Standby control system System There are 2 types automatic system switching and manual system
497. 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 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 the buffer memory a program may not operate properly due to device data mismatch after switching systems Diagram 7 17 shows operations when the system switching occurs before the tracking transfer processing is completed after outputting the output Y 7 16 7 4 Precautions at System Switching Occurrence PROGRAMMING CAUTIONS MELSEG TA series e Input is returned corresponding to output if Response input X10 gt d 2 i 4 Output Y10 ra O z jag z0 Program example pZ nO ni X10 0 SET Y10 a q oO Oo Z xe oO Error occurrence ne execution Scan execution y ype program type program Prepare tracking H anster data Prepare tracking T o Wait Wait transfer data Cag J J END 0 2 9 A Control system i os END a US a RES CPU module i i i 920 i ai Send i Send Send 4 4 Tracking transfer 4 Tracking transfer H Receive ees Receive PIS Cessing Receive Scan execution fi i type program D Standby system 5 i
498. tings Does not process it File Register Settings Holds the file register settings prior to system switching Not processed Direct Input DX Takes in X from the input module when executing the direct input instruction in a program after system switching Not processed Direct Output DY Outputs Y to the output module when executing the direct output instruction in a program after switching Not processed Intelligent Function Module Dedicated Instruction Executes the instruction in a program after system switching if the corresponding execution condition has been satisfied and does not execute it if it has not been satisfied Not processed FROM TO Instruction Executes the instruction in a program after system switching if the corresponding execution condition has been satisfied and does not execute if it has not been satisified Not processed Access Request from Intelligent Function Module 5 50 Ignores the access request Ea 5 3 The System Switching Function 5 3 4 Both Systems Operations After System Switching Not processed The redundant CPU cannot execute the low speed execution type programs 5 REDUNDANT SYSTEM FUNCTIONS 2 Network Module Operations MELSEC LA series Table5 37 Control System and Standby System Network Operations After System Switching Item MELSECNET H PLC to PLC network New Control System Network Module St
499. tinues execution Stops Starts operation when the RUN STOP switch is operated from RUN to STOP to RUN Operation status STOP PAUSE stop error Stops continues Stops continues Program execution type Takes over the current setting Takes over the current setting EI DI setting Takes over the current setting Takes over the current setting IMASK setting Takes over the current setting Takes over the current setting DUTY setting Takes over the current setting Takes over the current setting File register setting Takes over the current setting Takes over the current setting Instruction executed over several scans dedicated instruction Continues the instruction execution since operation was not executed before operation mode change Device memory including special relays and special registers Takes over the current status Takes over the current status With tracking setting Takes over the current status Takes over the current status Signal flow 3 Without tracking setting Takes over the current status Clears Turns off and then flashing RUN Operation status RUN Turns on continues Turns on when the RUN STOP switch is operated from RUN to STOP to RUN LED Operation status STOP PAUSE stop error Turns off continues Turns off continues BACKUP ONgreen and then DN ON green and then ON orange or
500. tiplexed Remote Sub master Station Switch to separate mode Control Calculating Multiplexed Remote Master Separate mode Standby Start calculation Multiplexed Remote Sub master Station Output Data Calculating Input data Input data MELSECNET H Remote I O network Remote O station Output Data Input data Input data MELSECNET H Remote I O network Remote I O station Diagram 5 44 Operations When Changing from Backup Mode to Separate Mode b Operations When Changing from Separate Mode to Backup Mode Separate mode Calculating Standby Switch to backup mode Control system Back up mode Operation stop Standby Input data PE mtenni Output Data mc Multiplexed Multiplexed Input data Remote Remote Master QnPRHCPU Sub master Station Station QnPRHCPU Input data Multiplexed Input data Multiplexed Remote Master eine i Output Data Station Station i eaka nnan Output Data Input data Input data l MELSECNET H 5 68 5 4 Operation Mode Change Function Remote I O network Remote I O station QnPRHCPU Output Data Input data Input data MELSECNET H Remote I O network Remote O station Diagram 5 45 Operati
501. to SM415 i New control system OFF 2a Sx T t cc E gt T4 Q lt SS N Extension of we Off time SoZ AZO We 2 t t SEa orw Standby system 3 New control system anr t x fixed cycle interval T System switching time t period between start of fixed pi cycle clock OFF and beginning 2 of system switching 0 lt t lt t on Z Zz Diagram 7 6 Operations of Fixed scan Clocks at System Switching 36 ag rare 2 Fixed scan Clocks SM420 to SM424 When system switching is complete SM420 to SM424 remain OFF in the new control system CPU module a Execute the DUTY instruction in the new control system CPU module to make SM420 A to SM424 usable in the new control system CPU module zg ZO Be Llu W Pema 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 SHI518 Perform DUTY ot Ht ouy Ki K SM420 instruction during SM1518 shutdown Diagram 7 7 Program That Executes Fixed scan Clock SM420 after System Switching Z o mod DI ET EO 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 second scan following system switching TROUBLESHOOTING 7 2 Cautions on Fixed scan Clocks Programs 7 9 PROGRAMMING CAUTIONS 7 10
502. to the CPU module whose first 5 digits of serial No is 09012 or later g Q fe ac i 5 a oc E 6 3 Communication between the Both Systems CPU Module and GOTs 6 41 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG A series GOT 1000 Series GOT A900 Series Ethernet connection Personal computer Ethernet MELSECNET H MELSECNET 10 Mode PLC to PLC network GOT 1000 Series GOT 1000 Series GOT A900 Series GOT A900 Series CPU directly connected CPU directly connected QCPU QnACPU Normal Normal station station GOT 1000 Series all p ae GOT A900 Series Sijaj gl e gl 2 al gle MELSECNET H PLC a 5 a to PLC network Tracking gable i CC Link Remote I O Remote device station station GOT 1000 Series GOT 1000 GOT 1000 GOT 1000 Go Tete Series Series Series Series CC Link connected Computer CC Link Ethernet link connected connection __ connected Remot
503. to the Q Corresponding Ethernet Interface Module User s Manual Basic for details 2 4 2 1 System Configuration 2 SYSTEM CONFIGURATION MELSEC TE ories 3 Communication via MELSECNET H PLC to PLC Network a Connecting Redundant System to MELSECNET H and MELSECNET 10 PLC to PLC Network A redundant system can communicate with Q series CPU modules connected to MELSECNET H PLC to PLC network The system can also connect to MELSECNET 10 PLC to PLC network and communicate with Q series QnA series and A series CPU modules N OVERVIEW b Pairing Settings and Relevant CPU Modules Pairing settings must be made using the control station network parameters when connecting a redundant system to MELSECNET H or MELSECNET 10 The following CPU modules include the network parameters for paring settings z O z ira 3 9 iE Z Q Redundant CPU F Em e High Performance Model QCPU z O Process CPU Z oO Basic Model QCPU Q4ARCPUs When connecting a redundant system to a network set any of the above CPU 2 modules as the control station 5 Ox CPU modules other than above can be set as the normal station only e 2 i ak a zd Refer to the following manuals for details on pairing settings for MELSECNET H agg Ez and MELSECNET 10 PLC to PLC networks 3 amp 8 ane L7 Q Corresponding MELSE
504. to the main base unit extension base unit l Connect the power cable to the power supply module Connect the battery connector to the CPU module battery connector Connect the CPU modules with the tracking cable When connecting the extension base unit connect the main base unit and the extension base unit by an extension cable Connect the network wiring to the network module Connect the I O module 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 reset switch neutral position 3 Make switch settings for the MELSECNET H remote I O network module 1 Check the following items and turn ON power supplies of the power supply modules of the main base units and extension base units simultaneously Wiring of power supply Power supply voltage RUN STOP switch position of system A system B CPU module STOP RESET L CLR switch position of system A system B CPU module Reset cancel Check that POWER LEDs of the power supply modules of the main base unit and the extension base unit in the systems A and B are turned ON green l Checking System A System B Check system A and system B by the SYSTEM A SYSTEM B LED of each CPU module 2 l Connecting to the PC in which GX Developer is Installed 1 Start up the PC in which GX Developer is installed 2 Connect the PC in which GX Developer is installed to the system A CPU module Re
505. tput frame No designation A BAy to 11D 15A to 1BDy maximum of 100 can be specified 0 No designation MS EG TE 1 or more Output frame No 0 Normal completion 25714 599 267 4 615 Data transmission result 1 or more Abnormal completion error code 4004 1024 800 2048 Transmission data count 0 No designation designation 1 or more Number of send data 4014 to 5FFy 801 to 9FFy Transmission data Data to be sent to an external 1025 to 1535 2049 to 2559 designation device App 46 Appendix 6 Precautions for Using Serial Communication Module APPENDICES MELSEC TA series The program example of sending data by the user registration frame of the nonprocedural protocol communication is shown in Diagram App 31 For the I O signal is X Y80 to X Y9F PROCESSING TIME FOR REDUNDANT SYSTEMS 0 PLS M50 3 HE mov k4 oo MOV H1234 D1 gt Sets the send data and the number of send data APPENDICES MOV H56AB D2 MOV HO Dio MOV H1 Dit INDEX MOV H5 Di2 MOV H3F2 D13 Sets the data to be written to the schedule specification area of the buffer memory MOV H3F3 Di4 MOV H8001 D15 MOV H8000 D16 MOV H41B D17 MOV Ho Di8 Writes each data of CR LF output specification to output 19 pe ROB DAO i frame No specification to the schedule specification area f Let TO H8 H400 DO K3 Set
506. trol system or standby system CPU module is changed from STOP PAUSE to RUN e Either control system or standby system CPU module is reset then unreset RESET L CLR switch is set to the neutral position e Either control system or standby system is powered OFF and then ON e The tracking cable is disconnected and then connected Operating Status Consistency Check The operation status consistency check cannot be performed during online program change Main base unit configuration The main base unit configuration check cannot be performed during online program change However if one of the following conditions occurs during online program change it will be performed e Standby system CPU module is reset and then unreset RESET L CLR switch is set to the neutral position e Standby system is powered OFF and ON e Tracking cable is disconnected and connected Parameter valid drive settings consistency check The parameter valid drive settings consistency check cannot be performed during online program change However if one of the following conditions occurs during online program change it will be performed e Standby system CPU module resets and clears reset e Standby system power is turned OFF and ON e Tracking cable is disconnected and connected Memory Card Setting Satus Consistency Check The memory card setting status consistency check cannot be performed during online program change 5 112 5 6 Writing To The Both Systems Using GX
507. twork system is used the MELSECNET H module 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 the MELSECNET H communication board is mounted For details of function requesting to switch system to the control system CPU module refer to the following manuals L gt Corresponding MELSECNET H Network System Reference Manual PLC to PLC network L gt Corresponding MELSECNET H Network System Reference Manual Remote I O network CONFIGURATION SYSTEM TRACKING CABLE Note that CAN T SWITCH may be detected in the control system CPU module when the above mentioned system switching is requested before the control system of the redundant system is started up Although the control system operates normally even in this case how to cancel CAN T SWITCH is shown below REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS o Zz Q O T o wW a O iva E 8 1 Troubleshooting Flow 8 25 8 TROUBLESHOOTING M100 KO K3 KO MELSEC TE ories 2 How to cancel CAN T SWITCH sp1588 HO KO sp1589 H KO sD1600 kO gt Cancel CAN T SWITCH detected by the control system CPU module after checking that the
508. ues zL Tracking cable communications 96 ze a2 Bus terminator Bus terminator g z Jels l gt E eee 0 Mia 381888888288588 g oojoojoojoajoojoojna a E 38 58l85258885 885 o DP Slave DP Slave Diagram 6 33 Operation of the PROFIBUS DP Master Module at System Switchingl 22 eC oO Zz E Q Q ae N W a 2 E 6 2 Redundant System Network Overview 6 39 6 2 6 PROFIBUS DP 6 REDUNDANT SYSTEM NETWORKS 3 4 5 6 MELSE TA ories Line redundant system The line redundant system allows the system configuration using 2 lines and either of the lines is used for slave station control When an error occurs at the controlling line the control is inherited to another line Station number setting Set the station number of the PROFIBUS DP master module with GX Developer and GX Configurator DP For details of setting method refer to the following manual lt gt PROFIBUS DP Master Module User s Manual Startup order of system A and system B When using the PROFIBUS DP master module startup order of system A and system B is unrestricted After the both system is started up and assigned their system Control system standby system data link is started 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 funtion version D or later b GX Developer version Use
509. ule Na 0 Maintenance and Inspection Included in package QCPU User s Cele UR Ce Ee CPU Module User s Design Manual Hardware inspection Details RL Manual Hardware Maintenance and O Program Fundamentals QCPU User s Manual Function Explanation Program Fundamentals S5 Multi CPU System QCPU User s Manual Multiple CPU System N 5 Redundant system QnPRHCPU User s Manual Redundant System Confirmation of connection methods for the power supply module base unit and I O module Details EE Outline Construction of the single CPU system confirmation of start up procedure and I O number assignment Details Construction of the multiple CPU system confirmation of start up procedure and I O number assignment oon Sa ey Details Confirmation of the sequence program configuration and memory Details Confirmation of the functions parameters and devices of the CPU module Details Confirmation of the troubleshooting and error codes Details OVERVIEW MELSEC fA series Table1 2 List of programming manuals of basic model QCPU w S wi gt O S Common PID control Process Structured control Instruction Instructions Instructions T
510. ule is in the 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 system CPU modules to the STOP status and then perform remote reset Remote operation Connection interface Target PLC PLC status System type Operation PLC Reset Connection target information Control Standby system ED STOP gt Reset COM1 0o00 lt gt PLC module STOP Control system C Extract memory card Station no Host PLC type Q25PRH AnA Col TC ots Operation mode Backup mode Specify execution destination Tracking cable Currently specified station Allstations Specific group System switching GX Developer sZ Standby
511. undant system restart the system by performing either of the following operations CONFIGURATION SYSTEM 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 TRACKING CABLE 2 The System A CPU module starts as a control system and the System B CPU module as a standby system b Set the RESET switches of System A and System B CPU modules to the neutral position simultaneously 1 When the System A System B CPU module has been reset reset the System A and System B CPU modules and then set their RESET switches to the neutral position simultaneously REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A 2 The System A CPU module starts as a control system and the System B CPU module as a standby system REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS o Zz Q O T o wW m O iva E 8 1 Troubleshooting Flow 8 19 8 1 7 When TRK INIT ERROR error code 6140 Occurred at Redundant System Startup 8 TROUBLESHOOTING 8 20 MELSEC TA eries 8 1 8 When CONTROL SYS DOWN error code 6310 to 6312 Occurred at Redundant System Startup 1 2 CONTROL SYS DOWN occurrence conditions CONTROL SYS DOWN occurs when either of the following operations is performed until the BACKUP LED is lit green during a startup of the redundant system e Either syst
512. unted on remote I O station TRACKING CABLE Input Device X remains ON OFF according to the forced ON OFF information Output External output ON OFF is continued according to the forced ON OFF information 2 Operation when standby system is powered off and then on standby system CPU module is reset and then its RESET switch is set to neutral position If the standby system is powered off the 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 REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol Table5 62 Operation When Standby System Is Powered Off and Then On Standby System CPU Module Is Reset and Then its RESET wW n gt n Zz lt j zZ gt W ve 7 2 Q O Z 5 u Switch Is Set to Neutral Position Item Module mounted on main base unit including Redundant CPU Module mounted on remote I O station Input Device X remains ON OFF according to the forced ON OFF information Output External output ON OFF is continued according to the forced ON OFF information REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 10 Redundant CPU Functions Restricted in Redundant System 5 131 5 10 1 Enforced ON OFF of external I O D REDUNDANT
513. ut changes according to device Y Output The external output changes according to device Y 2 Operation when standby system is powered off and then on standby system CPU module is reset and then its RESET switch is set to neutral position If the standby system is powered off the 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 remains the ON OFF status according to the forced ON OFF information of the control system CPU module Table5 64 Operation When Standby System Is Powered Off and Then On Standby System CPU Module Is Reset and Then its RESET Switch Is Set to Neutral Position Item Module mounted on main base unit including Redundant CPU Module mounted on remote I O station Input Device X remains ON OFF according to the forced ON OFF information Output External output ON OFF is continued according to the forced ON OFF information 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 systems simultaneously or cancel the reset 5 132 5 10 Redundant CPU Functions Restricted in Redundant System 5 10 1 Enforced ON OFF of external I O D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series 5 10
514. ute the check Executes the function Does not execute Executes the function 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 module Input it Output it Does not output it Input it Output it Does not output it Executes input Does not execute input Executes output Does not execute output Does not perform Executes the function f output it Does not perform Executes the function A output it Executes the function Executes the function Executes auto refresh Does not execute auto refresh Executes auto refresh Does not execute auto refresh AG Q series 3 When changing from the backup mode to separate mode the RUN LED will flash and programs will not be executed Set the RUN STOP switch of the standby system CPU module to RUN gt STOP gt RUN or use GX Developer to change from remote STOP to remote RUN With this setting the CPU module starts running and executes programs 5 4 Operation Mode Change Function 5 71 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Ol wW n gt n Zz lt ja zZ gt W ve 7 2 O O Z 5 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING RE
515. v o o Master station deta ink ype PLC parameter autostat_ v O ooo O y y y Mode Remote net Ver 1 mode All connect count Remote input R Remote output R Remote register Rw Remote register R w w Ver 2 Remote inputfRx Ver 2 Remote output RY Ver 2 Remote registerAWr Ver 2 Remote reqisterA Ww Special relay SB Special register S Retry count Automatic reconnection station count Stand by master station No PLC down select es Scan mode setting Asynchronous v Delay infomation setting JE eses s Station information setting Station information f ooo d Remote device station initial setting Initial settings f ooo d Interrupt setting Interrupt settings Fy SSS es eg SSS See E Indispensable settings No setting Already set Setifitismeeded No setting Already set g item Acknowledge XY assignment Clear Check End Cancel Diagram App 4 CC Link Network Parameter Setting Screen b 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 total number of systems connected to the CC Lin
516. ved from an external Receive data 1537 to 2047 2561 to 3071 device The program example of receiving data by the bidirectional protocol communication is shown in Diagram App 33 For the I O signal is X Y80 to X Y9F X83 X9F 0 4 FROMP H8 H600 DO K1 J Reads the number of receive data FMOVP DO ZO Stores the number of read data to index register Z0 T FROMP H8 H601 D1 KOZO Reads the receive data for the 7 number of receive data X30 X9F E Reads the receive error code 15 LFROMP H8 H258 D8000 K1 F Check the error description and take corrective action according to the error code stored in D8000 X83 2 o V Y Turns ON the read completion signal X60 24 Y8E Turns LED OFF and clears error code Diagram App 33 Program Example App 50 Appendix 6 Precautions for Using Serial Communication Module APPENDICES MELSE LA series Appendix 7 Restrictions on Communication via Module Mounted to Extension Base Unit PROCESSING TIME FOR REDUNDANT SYSTEMS 1 Command applicable in MC protocol via module mounted to extension base unit Table App 48 shows applicability of connection destination specification for each command of MC protocol via a module mounted to the extension base unit Table App 48 Applicability of connection destination specification of each command from request source i w Q a Z w a a lt
517. ween the backup mode and separate mode 6 Refer to Section 5 3 for switching between the backup mode and separate mode E Switch the operation mode to the debug mode in the redundant parameter settings BS no 1 Backup Mode The backup mode is for normal operation of redundant system If a fault or failure occurs in the control system the standby system takes over the M control and continues the system operation 5 To enable the standby system to continue the system operation when the control 2 system goes down the data of the control system must be continuously transferred to Z the standby system through the tracking cable Refer to Section 5 5 for details on the tracking function T A Heer Stopping Calculation 5 7 System L we E ree al ie U 2 5 Tracking cable 9 An error occurred in the 2 NZ Control System z2 ake A ag System A Control End calculation System B Standby Begin calculating mE System gt Standby System gt Control System 5 m a l f Ki a J D g k HH E 2 z e z g zv z Zg F Trackin
518. xclusive station E X TE v No setting X Intelligent device station Default Cancel Exclusive station 1 v O No setting Diagram App 5 CC Link Station Information Setting Appendix 4 Sample Programs when Using CC Link App 17 APPENDICES MELSEC TA ories Appendix 4 5 Sample Program 1 When using the QJ61BT11N whose serial No is 07112 or later a Sample Program Name CHANGE 1 Sample program overview flow CHANGE 144 Set 141 to be valid Forcibly change the system that Step 0 to 11 communicates with the CC Link Step 46 to 49 IRET Refresh the remote devices and enable system switching Step 12 to 32 Initialize devices at the time of system switching Step 33 to 34 Refresh the CC Link Step 35 to 44 FEND Diagram App 6 Sample program overview flow App 18 Appendix 4 Sample Programs when Using CC Link APPENDICES MELSEG TA series 2 Sample Program PROCESSING TIME FOR REDUNDANT no su4o2 a o h Fov HOFFFF D100 Ka 7 T S1518 D H wav w200 ozs Adds 141 to the allowable interrupt defaults 10 b o J to 131 148 to 1255 oF iwask 0300 j 1 ei J suso k iH Bwv KAYID00 6352 x10 J Performs a refresh of RY Y1000 to Y109F r BMOV 5224 K4x1000 KIO Performs a refresh of RX X1000 to X109F us Buoy moo Gro K20 Performs a refresh of RWw W1100 to W1
519. xecuted standby master switching ON _ instruction acknowledged 5B443 Refresh instruction complet status at standby OFF Not executed master switching ON Switching complete PEE OFF Not acknowledged B45A M hing r knowledgment SB45 aster switching request acknowledg ON Request acknowledged sapi OFF Not complete B45B M hing r complete SB45 aster switching request p ON Complete SW443 Refresh instruction at standby master switching 0 Normal result Other than 0 Stores an error code Appendix 4 Sample Programs when Using CC Link APPENDICES MELSEC LA series 3 Refresh Devices Remote input RX remote output RY and remote register RWr are refreshed by the program in a redundant system Make the refresh settings of special relay SB and special register SW in network parameters The CC Link refresh devices and refresh ranges for the system in Appendix 4 1 using 5 stations are shown in Table App 12 Change the 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 PROCESSING TIME FOR REDUNDANT SYSTEMS APPENDICES Table App 12 Refresh Devices Buffer Memory Head 1 Number of Data Device Name Transfer Range Device Used seme me a anaes estes Remote Input RX RX0 RX9F 224 E0H X1000 X109F Remote Output RY RY0 RY9F 352 160n 10 Y1000 Y109F Remote Register RWr
520. y 00 to the communication protocol APPENDICES b Transmission specification area after switching Address 914 131p 1 Specify the transmission specification after mode switching 2 Write 0000 when initializing settings set by GX Developer 3 When setting the arbitrary transmission specifications transmission specifications other than set in GX Developer write the value corresponding to ON OFF of the relevant bit shown below Specification of 1 ON 0 OFF of the relevant bit is the same as that of transmission setting of GX Developer INDEX b15 bl4tob8 b7 b6 b5 b4 b3 b2 bl b0 1 00y to OF 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 CH1 side 1 004 to OFy 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 CH2 side x x A Setting OFF 0 ON 1 Operation setting Independent Linked Data bit 7 8 Parity bit Notset Set Odd even parity Odd Even Stop bit 1 2 Sum check code _ Notset Set Write during RUN Prohibited Allowed Setting change __ Prohibited Allowed Bit position Description Communication speed 3 Fixed to ON 1 2 Specify 80004 when selecting GX Developer connection for the switching mode No specification 3 The following shows the specified value of the communication speed Communication speed Bit position Communication speed Bit position
521. y System LED common to System A System B i e Control CPU Module LED System Standby System Control Standby LED Name System System System A System B CONTROL 4 11 Running CPU Modules Set the RUN STOP switch to the RUN position in this order standby system System B CPU module control system System A CPU module CPU module Power Switch STOP RUN Diagram 4 13 CPU Module RUN STOP Switch Position and Setting 4 10 Confirming the Control System Standby System 4 13 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE A ii 2 gt a zZ lt fa 2 fa w aj X lt aS Of ze aw REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING PROCEDURE FOR STARTING UP A REDUNDANT SELL Mi aL 26 FY eries Memo 4 14 4 11 Running CPU Modules D REDUNDANT SYSTEM FUNCTIONS MELSEC TE ories CHAPTERS REDUNDANT SYSTEM FUNCTIONS This chapter explains the redundant system functions 5 1 Basic Concept of Redundant System A redundant system consists of two basic systems each of which includes a power supply module CPU module main base unit and network module To configure a redundant system connect the basic systems on which above modules are mounted with a tracking cable Please refer to Section 2 1 for system configuration
522. y check Redundant parameter Operation settings Tracking settings Start mode setting Mode ee Initial start mode 2j It will become Hot start mode during system switching Standby system watch setting IV Check the error in Standby system Debug mode setting Do not start with Debug mode C Start with Debug mode Backup mode setting IV Check operating status consistency Cancel Default Diagram 5 13 Operation setting Screen 5 1 Basic Concept of Redundant System 5 1 4 System Consistency Check 5 19 SYSTEM PROCEDURE FOR STARTING UP A TRACKING CABLE CONFIGURATION OVERVIEW REDUNDANT SYSTEM Ol Lu 2 gt no E Zz lt q Zz Q W a 7 2 O QO 2 u REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS Mi aL 20 A ceries 3 Basic System Configuration Consistency Check a Check points The basic system configuration consistency check means checking the followings If the number of slots of the main base unit has been set in the PLC parameter O assignment only the specified number of slots will be checked e CPU module model e Model and type of modules mounted on each slot in the main base unit e Network module mode settings An error occurs because the CPU module type name is different Q12PRHCPU Q25PRHCPU MODE RUN MODE RUN
523. ystem Switching High i Control system powered off e Control system CPU module reset e Stop error in control system CPU module e Execution of system switching instruction e System switching operation using GX Developer e System switching request by network module aj A Po Low 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 5 40 5 3 The System Switching Function 5 3 1 System Switching Method 5 REDUNDANT SYSTEM FUNCTIONS Mi ELSEG A series b Error message displayed on GX Developer If the system switching is actually executed due to another reason for system switching when an attempt of system switching has been made using GX Developer the error message Diagram 5 32 will appear on GX Developer OVERVIEW E MELSOFT application Please confirm the system i System switching was previously executed by one Factor lt ES 010a424F gt CONFIGURATION SYSTEM Diagram 5 32 Error Dialog Box Displayed on GX Developer 4 Operations When System Switching is Executed in the Standby System CPU Module If the manual system switching request is issued to the standby system CPU module the system switching will not be executed Table5 24 indicates the operations performed when
524. ystem s f Stop Error has a gL ah normal station becomes E occured the sub control station and q S E B maintains the data link Tracking cable J Q IZ o 95 Diagram 6 8 Operation When System Switching Occurs Due to Control System Error cs oO Zz E Q Q ae i a O oc E 6 2 Redundant System Network Overview 6 9 6 2 1 MELSECNET H PLC to PLC network 6 REDUNDANT SYSTEM NETWORKS MELSE Eseries 3 Redundant System Operation when a Communication Error Occurs in the MELSECNET H PLC to PLC Network a Continuation of Data Link via System Switching When a communication error occurs in the MELSECNET H PLC to PLC network system switching is performed according 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 switching is completed the new control system network module continues the data link The standby system network module does not issue a system switching request even when a communication error occurs in the MELSECNET H PLC to PLC network 6 10 6 2 Redundant System Network Overview 6 2 1 MELSECNET H PLC to PLC network 6 REDUNDANT S

QnPRHCPU User`s Manual (Redundant System)

Contents

Download Pdf Manuals

Related Search

Related Contents