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QnPRHCPU User's Manual (Redundant System)

1. 2 Communication between External Devices and the Standby System CPU Module if 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 Communication can be performed by MC protocol only E 0 mS Multiplexed Remote Master Station Multiplexed Remote Sub master Station 9 z nO Control system LO Standby system i a g Cn cl e O a 2 f 8 i j i 2 jme l e T4 HE O a pH E z z oye R i
2. g 8 N a g gl BLE i 3 a E a 3 j a amp E l f g E z ical tal L a lt A m a me Tracking cable ne gt O no O MELSECNET H Remote I O network Remote I O Remote I O Remote I O station station station g g x T u F Fie lt B i 2 ag i E g E S a E z Multiplexed Remote Sub master Station Master Station operation a r mS Z Control system HSE a Doc BL g i ag DES ih Do al HRE SeS x I iS al Oga Error fault Ol el Thr i J is NG 38 el IHE oS al am Q ji Tracking cable p L MELSECNET H Remotef1 O network E qZ Remote I O Remote I O Remote I O es station station station 5 5 g 7 g 2 z a f ez ES faire I are f ER a j i j w w B w ai Diagram 1 5 System Configuration for MELSECNET
3. 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 gt advance 3 Pe O E Ethernet g zo j n zZ Control system Standby system ao ne IE E mi z m E i g aael H E al a H B KHL a E i z J e e J a q Tracking cable z z x O Control and network pad xr y 7 automatic system switching Cae wo Ethernet Be z aza Es Standby system i Control system Sam i e ae 7 _ THE BJE A D 8 g el 0 al z z z a g H AEH amp gt Tracking cable E Ze Diagram 1 9 System Configuration for Ethernet 2 az W D a u 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 redu
4. Table6 1 GX Developer System Specification and Communication Paths System or A TOEA Communication Path S Specification m 3 System A Control System System B Standby System System not te i 3 Sp ak S specified default g E Not specified Select this option to communicate with only the Default CPU module connected to GX Developer O GX Developer Communicate with the connected CPU module lt o e Select this option to communicate with the control System A Control System System B Standby System g B e g fa m a upr system CPU module using GX Developer Control system 3 F B ao x 5 e lel If system switching occurs communication is done 5 with the new control system CPU module 4 ater EZ Tracking cable If the CPU module connected to GX Developer is a Control re s GX Developer Communicate with the control system CPU module the control system communication is done with E System System A Control System System B Standby System a that CPU module 3 Control system Aj E If the CPU module connected
5. POINT After system switching the new control system will start up in the Hot start mode z m regardless of the start mode settings z 2 Hot start mode This mode is for performing the operation from when holding the device 5 n z O Some devices such as the step relay and the index register will be cleared 5 As holding the devices even when the redundant system goes down due to power 3 er Le OFF or CPU module reset the system can continue the operation when it is powered oZ nO on or the CPU modules are unreset RESET L CLR switch is set to the neutral position System A Control System System B Standby System a Mos I F nf a7 a a gE a g E O Control using Hot start mode SIME z B e A a g E p amp Ii B E0 e x al fi Fy Es 3 FI al jlo s z a BE 3 a v i Tracking cable D100 1234 Power the system off and x D101 2345 back on ah wz System A Control System System B Standby System 3 g a fz B T fz E EE Thr Start in Hot start mode m J e 3 5 a g Hel amp _ g alH e 5 a a 8 m N Tracking cab
6. 1 Communication between External Devices and Control System CPU Module i 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 X Appendix 7 1 S In addition when system switching occurs the communication timeout will sa Lu occur since both old system and new system cannot respond Therefore 2 nO perform retry processing by MC protocol Control system Standby system g Ww H z S 5 E g Tracking cable z E Serial communication Extension cable modules woe ange When specifying control system using MC protocol Lu D gt wn ca x Z2 System switching ge activated as W D ew Control system Standby system CONEINGON er W wn gt n j A Ed a Zz fa W a n X x e z E W zZ Tracking cable Serial communication Extension cable module 0 zZ o 56 z2 ao When specifying control system using MC protocol o zZ 5 Q Diagram 6 29
7. co co ai2PRHcPU 1 gt oe BACKUP 7 gt RUN CONTROL __ L 2 ee USER svetem sE 8 3 ees oe 9 4 a 10 5 6 Diagram 8 1 CPU Module LEDs Table8 1 LED Names and Explanations No Name Explanation Indicates the CPU module mode 1 MODE LED On Green Q Mode Flashing Green External I O Forced ON OFF has been registered Indicates the CPU module operation status On The CPU is Running The RUN STOP switch RUN position Off The CPU has Stopped The RUN STOP switch STOP position The standby system CPU module in backup mode The RUN STOP switch RUN position 2 RUN LED An error that stops operation has been detected Flashing The RUN STOP switch is set to the STOP position to write parameters programs into CPU and then the switch is returned from the STOP to RUN position The standby system CPU module for which the operation mode is switched from backup mode to separate mode On The self diagnostics error that does not stop the operation other than battery error is detected The settings have been made by the parameter so that the operation is continued when an error is detected 3 ERR LED Off Normal Flashing An error that stops operations has been detected Automatic write to the standard ROM is completed
8. System B Standby System eem A e B e H E o RUN Control fS Execute program system s T Tracki bl tandby Normal Standby racking cable system RUN i Stop program y Automatic switching occurred System i Sysieme Begin Control C VN witching i Standby System gt y J Control System e al amp Standb a gt 5 Stop Error Sein Control RUN H g amp 5 system f Execute program a i Tracking cable C y E Diagram 5 23 System switching operations when a control system error occurs 5 3 The System Switching Function 5 3 1 System Switching Method D REDUNDANT SYSTEM FUNCTIONS MELSEC KE eries b System switching requested by the network module e When the control system CC Link IE Controller Network module MELSECNET H module or the Ethernet module detects a communication OVERVIEW error or wire break the module requests system switching to the CPU module The standby system CC Link IE Controller Network module MELSECNET H module or the Ethernet 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 communication failure with DP Slaves the module requests system switching to the CPU module The standby system PROFIBUS DP master module does
9. qed Control system Standby system i Normal station a el g Communication not a amp al E possible malfunction z 5 5 severed network cable T il So 8 B Tracking cable Control and network automatic system switching Diagram 1 4 System Configuration for CC Link IE Controller Network 1 For restrictions of the CC Link IE Controller Network interface board refer to the following manual CC Link IE Controller Network Interface Board User s Manual 1 8 1 2 Features OVERVIEW MELSEC TE eries b MELSECNET H Remote I O Network MELSECNETI H remote I O stations can continue the operation even when control standby system switching occurs gt Section 6 2 2 OVERVIEW Multiplexed Remote Master Station Multiplexed Remote Sub master Station Control system Standby system y
10. CC Link E REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A GOT1000 Series Diagram 6 36 System When Connecting GOTs to CC Link REDUNDANT SYSTEM FUNCTIONS 1 GOT connection methods The connection method for connecting GOTs to the CC Link is referred to as CC Link connection In this method mount a CC Link communication unit GOT dedicated product to a GOT and then connect it to the CC Link ez 2 Communication method The GOT communicates with the control system CPU module of the master station by specifying station No 0 in the GOT Even when system switching occurs the network module of the new control system W wn gt n j A Ed a Zz fa W a n X x e z E W Z 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 g the GOT always monitors the control system zg For details refer to the following manual 95 L gt GOT1000 Series Connection Manual Mitsubishi Products as g 4 i 3 e 6 3 Communication between the Both Systems CPU Module and GOTs 6 48 6 3 2 When Connecting GOTs to CC Link 6 REDUNDANT SYSTEM NETWORKS MELSEC TE eries 6 3 3 Communication when the GOT is Connected to CC Link IE Controller Network MELSECNET H or MELSECNET 10 P
11. a KA E Tracking cable Power OFF gt ON Power OFF ON Diagram App 17 The system when both systems are simultaneously powered ON 1 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 J System B System switching o Tracking cable Diagram App 18 The system when System B is switched to the control system through a system switching instruction App 27 Appendix 5 Method for Starting up the Previous Control System APPENDICES MELSEC KEY eries F lt 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
12. Lu wn gt wn Zz a a ae fa Lu a o Z O O Z Le Tracking cable Redundant operation Connection target information Connection intetace COMI lt gt PiE modde separate mode Target PLC f Stationno Host PLC type Q25PRH change operation a reas z Change to separate mode F System type Control system Operation mode Backup mode GX Developer 7 A Remote operation Memory copy progress status z 2 Tera _ _ BACKUPEEIX ON amber 3 aa Run in separate mode a Be Memory copy flashing mw BACKUP E lt ON amber ce Control system Select Separate mode E 3 E E g a 7 22 Tracking cable z 2 rar ao GX Developer o Diagram 5 33 Operation when Changing from Backup Mode to Separate Mode 5 e 1 When changing from the backup mode to the separate mode the RUN LED of the standby p WwW system CPU module will flash and will be in a stop status z 5 a 5 4 Operation Mode Change Function 5 58 D REDUNDANT SYSTEM FUNCTIO
13. agi oim M Tracking cable mi 35 0 1 38 Jta D 89 3 3 52 ar 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 4 POINT 1 Always power OFF the standby system or set the RESET L CLR switch of the standby system CPU module to RESET before connecting or disconnecting the tracking cable 2 To connect or disconnect the tracking cable hold it by the cable connector 3 2 3 3 Connecting and Disconnecting a Tracking Cable TRACKING CABLE MELSEC TE eries 2 Connecting a Tracking Cable a Make sure that you are using the correct tracking cable connector for System A or System B Refer to Section 3 2 and Section 5 1 1 for confirming System A and System B OVERVIEW b Hold the tracking cable connector and align it with the CPU module TRACKING connector Redundant CPU a TRACKING connector CONFIGURATION SYSTEM oO Connector E Tracking cable Ww ml a lt 3 0 zZ x QO lt ao Diagram 3 2 Checking the Connection Orientation of the Tracking Connector c Connect the tracking cable connector to the CPU module TRACKING connector ae wn P lt wn i Redundant CPU woe Kaz Soa pE E o W E i gt wn 3g Diagram 3 3 Connecting the Tracki
14. Lee ooo000 ooo O fi LA E ara ara LC Tracking cable TRACKING CABLE CC Link Remote I O station station No 2 Standby Master Master Station Station Operation Operation Station No 1 Station No 0 System A Control System y System B Standby System l Stop Error D Tracking cable CC Link Remote 1 O station station No 2 REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A nooo oo0000 i CArmnICArma Oooo m m a REDUNDANT SYSTEM FUNCTIONS ez Diagram 6 26 Operation at System Switching due to Control System Error W wn gt n j A Ed a Zz fa W a n X x e z E W zZ PROGRAMMING CAUTIONS TROUBLESHOOTING 6 2 Redundant System Network Overview 6 32 6 2 4 CC Link 6 REDUNDANT SYSTEM NETWORKS 6 33 MELSEC TE eries b When System Switching Occurs due to Communicat
15. SystemA fesul o 1 2 3 T7 Slot number System B cpu o 1 2 3 4 Slot 0 is 0 points redundancy oj o a o i a a a a I a E a a ac 25 2c 2s a g amp e e E _ lt el gt ES VO Number z A 2 eleje e IERE g TEE eae IE cy S z On On On e allal s J e E a e Tracking cable Module installation range Module installation range A u pa e a Sa Diagram 2 13 Number of Slots Occupied by Redundant CPU and I O Numbers of Main Base Units ws IE 2ot pE E Of d beg o W E i gt wn zn z 56 ZE 50 as ew W 12 gt wn Zg om ZO Be W Ww cz 0 z Yn Z 2 5 O z3 20 o zZ fe ag N WwW a a hd 2 4 System Configuration Cautions 2 21 SYSTEM CONFIGURATION 6 Module MELSEC TE cries 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 I O station where the Redundant CPU is mounted The target modules of online module change are shown in Table2 5 Table2 5 Target Modules of Online Module Change Hot Swapping Mounting position Main base unit Function version Extension base MELSECNET H where Redundant CPU is mounted unit Remote I O station Input module on O O Output modu
16. leo Cols Memory copy progress status E py E4 I i q H iemory copy 3 Transfer E Command Spare CPU module 2 Installing the CPU module 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 GX Developer e Special relays and special registers 5 111 5 7 Memory Copy From Control System To Standby System D REDUNDANT SYSTEM FUNCTIONS M als 26 fel 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 ae Set by User Type Number Description Remarks or System Turn on this relay to start memory copy after storing Specific to control SM1595 j User 3D1H into SD1595 system CPU module Applicable to both This relay turns on during memory copy control system and SM1596 i System 4 This relay turns off after memory copy standby system CPU modules Special i 1 p This relay turns on after memory copy Applicable to both Relays Turn off this relay when starting memory copy SM1597 System control system and In the case of memory copy by GX Developer GX seer standby system CPU D
17. 2 Redundant System Operation at System Switching due to Control System Error When system switching occurs due to a control system error the data link is g gt continued by the network module mounted on the new control system 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 module is the control station of station No 1 and the standby system network module is the normal station of station No 2 Ei as Normal station Normal station Station No 3 Station No 4 i g g a a q S 0 zZ x 6 ee CC Link IE Controller Network gt ii Control Control station Standby Normal station x la system Station No 1 system Station No 2 Q lt Re fz a g s g X 5 z SEE Talg A ian aos ee P Lu EZ ql Bre g 828 4 a i tor a a Tracking cable ii Stop error occurs in the F Normal station control system CPU module 7 Station No 3 22 gO E ge 8 az H z l ERr ez lt CC Link IE Controller Network gt Control station Station No 1 Normal station Station No 2 Sub control station W wn gt n j A Ed a Zz fa W a n X x e z E W zZ Standby system
18. Diagram 5 88 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 Q12PRHCPU Q12PRHCPU MODE BACKUP MODE BACKUP RUN CONTROL RUN CONTROL ERR al SYSTEMA ERR SYSTEMA USER SYSTEMB ON green USER SYSTEMB BAT BAT BOOT BOOT ON red OFF ON green Diagram 5 89 LED Indications during Standby System CPU Module Operation 5 7 Memory Copy From Control System To Standby System 5 118 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu wn gt wn A lt a fa W a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG Q series b Memory Copy Operations Diagram 5 90 illustrates the processes that take place in memory copy Memory copy preparation Perform memory copy Control system Standby system Control sys
19. 6 3 Communication between the Both Systems CPU Module and GOTs u fi When the GOT communicates with the standby system control system CPU module the 3 communication target can be specified by the station No The GOT cannot specify the system control system standby system system A or system B x Table6 7 shows connection method and connectability when the GOT is used in the redundant system For the restrictions when the GOT is used in the redundant system s3 wW T refer to the following manual 2 a 5 F z r O L gt GOT1000 Series Connection Manual Mitsubishi Products 2 Table6 7 Connection Method of GOT and its Connectability in Redundant System Connection method Connectability Remarks m Not connectable since the stop error EXTEND BASE ERR error lt Bus connection x 4 code 2010 occurs to the CPU module Z CPU direct connection O z Not connectable since the serial communication module cannot be Computer link x mounted to the main base unit where the Redundant CPU is connection mounted Main base unit where Eth 4 fi Redundant CPU is Se O Bak mounted CC Link IE Controller O __ mE 5 Network a S 5 MELSECNET H PLC to 9 g 5 PLC network O Tbe MELSECNET 10 PLC to PLC network O CC Link connection fa ie Bus connection x Not connectable No error occurs to the CPU module 7 Computer link Z Z connection O Bis az Ethernet connection O
20. eol 1eot a Tracking cable Replace after turning OFF the standby system power GX Developer Diagram 8 30 System where Standby System Network Module Is Replaced 2 Replacement Procedure The replacement procedure for network modules is indicated in Diagram 8 31 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 3 Replacing Module in Redundant System 8 3 5 Network Module Replacement Procedure 8 TROUBLESHOOTING M ELS 26 Fel series Disconnect the network cable from the target 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 manual of the used network OVERVIEW module Connect the network cable to the network module CONFIGURATION SYSTEM Refer to the manual of the network module
21. Tracking cable MELSECNET H Remote I O network Diagram 6 16 Network Module Station No Settings 5 Network Parameter Settings In the network parameters for system A and system B set the network type identically as MNET H multiplexed remote master W Network parameters Setting the number of Ethernet CC IE MELSECNET cards Network type Starting 1 0 No Select MNET H Multiplexed remote master Necessary setting Nosetting Akeadyset Setiftisneeded No setting Aleady set Valid module ZAS during other station access Please input the starting 1 0 No of the module in HEX T6 bit form Check Acknowledge XY assignment Routing parameters Assignmentimage Group Settings Diagram 6 17 Network parameter Setting the number of Ethernet CC IE MELSECNET cards 1 In the debug mode the CPU module uses the parameters for system A to operate Therefore the station set as system B in the network parameters becomes absent station disconnected station Refer to the following manual for network parameters L7 Q Compatible MELSECNET H Network System Reference Manual Remote I O Network 6 21 6 2 Redundant System Network Overview 6 2 2 MELSECNET H Remote I O network 6 REDUNDANT SYSTEM NETWORKS 6 7 MELSECTE cries
22. System switching Input by forced ON OFF of external I O REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Forced ON OFF information tracked J 4 H from control system CPU module ol Tracking cable a C MELECNET H remote I O network Remote I O station Lu wn gt wn Zz a a rs 2D fa Lu a o Z O O Z Le GX Developer Ee Output by forced ON OFF of external I O Y120 0N l 121 0N Update statis Cher all Coe Diagram 5 97 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 changed the external I O forced ON OFF can be continued according to the forced ON OFF information before operation mode change REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS 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 externa
23. iestie3lm Tracking cable TRACKING CABLE GX Developer Replace after using GX Developer to switch over to the standby system Diagram 8 22 System where Control System Power Supply Module is Replaced Replace the power supply module for the standby system after turning the power supply for the standby system OFF The standby system power supply can be turned off even when the redundant system is active REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Power supply module Control Standby system system REDUNDANT SYSTEM FUNCTIONS ICAIQICAIINA Tracking cable Replace after turning OFF GX Developer the standby system power REDUNDANT SYSTEM NETWORKS Diagram 8 23 System where Standby System Power Supply Module is Replaced 41 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 C gt Section 8 3 3 PROGRAMMING CAUTIONS o e o zZ O O ol w l D 2 O hA 8 3 Replacing Module in Redundant System 8 38 8 3 2 Power Supply Module Replac
24. eaea l it ley am OOGG ogag COU TCOL L i Tracking cable TRACKING CABLE GX Developer Replace the redundant power supply module 1 Procedure for Replacing Redundant Power Supply Modules The procedure for replacing redundant power supply modules is shown in the Diagram 8 25 Confirming the Replacement Target Power Supply Module Identify the faulty power supply module using the System Monitor of GX Developer REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Power OFF the Target Power Supply Module Removing the Wiring Disconnect the power supply cable from the target power supply module Replacing the Power Supply Module 1 Remove the power supply module from the main base unit 2 Mount the replacement power supply module to the main base unit Refer to the QCPU User s Manual Hardware Design Maintenance and Inspection REDUNDANT SYSTEM FUNCTIONS regarding disconnecting and attaching power supply modules REDUNDANT SYSTEM NETWORKS Wiring Wire the power supply cable to the power supply module Power ON the Power Supply Module Power on the new power supply module Confirming the POWER LED of the Power Supply Module Confirm that the power supply module s POWER LED is ON and that power is being supplied properly Completed Diagram 8 25 Redundant Po
25. ma ICAINICAIINE Tracking cable AN Replace after using GX Developer to switch over to the standby system GX Developer Diagram 8 27 I O Module Replacement System during Power ON POINT The I O modules of control system and standby system cannot perform online module change hot swapping using GX Developer when connecting the extension base unit to the CPU module whose first 5 digits of serial No is 09012 or later When replacing modules online using GX Developer in other than above cases refer to the following manual C gt QCPU User s Manual Hardware Design Maintenance and Inspection 8 41 8 3 Replacing Module in Redundant System 8 3 4 I O Module Replacement Procedure 8 TROUBLESHOOTING MELSEC KE eries 3 Replacement Procedure during Power OFF The I O module replacement procedure is shown in Diagram 8 28 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 replacing the I O unit for the control system use GX Developer to switch it to the standby system OVERVIEW Refer to Section 5 2 for system switching using GX Developer Turn the Standby System s Power Supply OFF Removing the Terminal Block Conne
26. W wn gt n H A lt x a Zz a W a n X x e z E W zZ Remote I O station Output is preserved Remote I O station Output is preserved station No 2 during system switching station No 3 during system switching 9 Diagram 6 15 Output Status during System Switching 22 E o gt a ao oO Z E O 0 25 N W I a O o E 6 2 Redundant System Network Overview 6 20 6 2 2 MELSECNET H Remote I O network 6 REDUNDANT SYSTEM NETWORKS M ELSEG Q series 4 Network Module Station No Settings Set station No 0 multiplexed remote master station for the network module which is mounted on system A Set any of station No 1 to 64 for the network module that is mounted on system B 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 Multiplexed Remote Master Station set to station No 0 Multiplexed Remote Sub master Station set to any station No between 1 64 System A System B Coll Ne ol ists
27. W wn gt n j A Ed a Zz fa W a n X x e z E W zZ Normal transmission o z Ss System A Control System System B Standby System Z 2 _ e h bl a E l OF 3 F f p a ra Communication I ao f not possible gt i a a a reel cs ae Ew a a aj o l Tracking cable o Diagram 6 22 Operation at Communication Error Detection 3 ag i a 6 2 Redundant System Network Overview 6 28 i 6 2 3 Ethernet 6 REDUNDANT SYSTEM NETWORKS MELSEC TE eries 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 occurs In this case review the communication path and restart the communication
28. 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 e 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 The following stop error occurs in the standby system backup mode CPU module only FILE DIFF error code 6001 e When reconnecting the tracking cable If the FILE DIFF occurs in the standby CPU module Use the dip switches SW2 SW3 of the control system and standby system CPU modules so that the settings will be consistent 1 Ifa 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 25 5 1 Basic Concept of Redundant System 5 1 4 System Consistency Check D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries 5 1 5 Self Diagnostics Function 1 Self Diagnostics Function ai The self diagnostics fun
29. System A System B i pvV J Control System Standby System i p Standby System Control System 1 R Ag E A ji Normal Standby Standby E H E g RUN 4 system Control RUN p Bal Stop program i system Execute program a Ay Jo IHE ta _ e aj fa 1 l Tracking cable J L y J GX Developer Diagram 5 26 System Switching Operation by GX Developer 5 3 The System Switching Function 5 38 5 3 1 System Switching Method OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series EJPOINT 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 iy The system switching is not allowed Please switch the system again after turning ON the manual change permission flag SM1592 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 a When the system switching instruction is executed in the control system C
30. 3 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 f Refer to the following manual for network parameters 3 Q Corresponding Ethernet Interface Module User s Manual Basic Redundant settings KENIS Issue system switch in Cable disconnection timeout SETHE SCs SO Em Cable disconnection timeout setting 20 sec 0 0sec 30 0sec Station number V Issue system switch in communication error Made One z System switching settings when communication error occurs Fixed buffer Station number and mode setting System B Setting Protocol Open system Fixed buffer oa Station number 2 mi exist Procedure exist Mode Online zi Procedure exist IP address settings Input format DEC I Enable auto open UDP port System A Enable GX Developer UDP communication port I Enable GX Developer TCP communication port Es I Enable FTP communication port System B T Enable HTTP communication port 122 E a a Check End Cancel Diagram 6 23 Network Parameter Setting Screen 1 In the debug mode t
31. nooo N ee A a E l f Ale J arso g U B HE ial al ejo Tracking cable A I I ee Remote I O module MELSECNET H Remote I O network e Serial communication Oo I module Remote I O station Remote I O station B ron t iar a Le COMES 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 39 6 2 Redundant System Network Overview 6 2 5 Serial Communication Modules 6 REDUNDANT SYSTEM NETWORKS M als 26 fel ceries
32. lt ON green Control system om mode BACKUP lt ON green Standby system zp CONEINGE NE COU NCOL Tracking cable GX Developer Diagram 5 34 Operation when Changing from Separate Mode to Backup Mode es The operation mode can be changed from the separate mode to backup mode by either of the following methods Powering on system A and system B simultaneously 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 the standby system CPU module resumes the Consistency Check Between Systems AandB When returning to the backup mode make sure to make the settings so that the control system and standby system will be consistent in advance Refer to Section 5 1 4 for details on the Consistency Check Between Systems A and B 5 4 Operation Mode Change Function D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries 2 To change the operation mode back to backup mode use the same GX
33. v The RUN LED does not light up A system switching has occurred 8 3 8 1 Troubleshooting Flow TROUBLESHOOTING 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 ai powered on i O The MODE LED does not light up Not light or lit solid red C37 QCPU User s Manual z The power supply module s Hardware Design 5 POWER LED Maintenance and Inspection E wir 26 HO Is current being supplied i power supply NO Check the wiring and turn on the Is the power supply power f module cabling a a normal NO YES Z Does the MODE LED light up Z Connect GX Developer to the CPU module a Is communication with G Perform a PLC diagnostic and troubleshooting x 5 Developer possible based on the diagnostic results Q lt 5 p55 E o Is the CPU module s Pe i i i RESET Position After resetting using the RESET L CLR switch RESET L CLR Switch set return the switch to the neutral position to the neutral position a D Neutral position A Does the MODE LED light up Ep z Replace the power supply module 5 and confirm the POWER LED is lit 2 o D5 rw YES Does the MODE LED light up Power supply module hardware fault im E n The following modules ma
34. 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 z system A communication is continued with system A via system B 3 J GX Developer 5 l Ethernet J l a The line is down System A System B lt Control System Standby System se moo es an ae all B B m OZ i ALEG F E E a 8 i System switching 6 ey B dal g HE 3 a 8 Tracking cable a q 2 When the line is down 9 GX Developer communication continues 5 via an alternate path T E pp ____ie hnoo Ethernet _ System A X System B z Control System Standby System H a as a Bak P e O a zs g k E a Bl Hie n z I x ZE a BIB a e H TED 2 a Z 2 i ang Tracking cable 1 a x Diagram 6 5 Communication continuation through system switching a z N 5a 6 POINT 25 az Communication via a tracking cable is carried out when the route system s power cara supply is on and the tracking cable is connected properly Communication via a tracking cable is not carried out in the following cases ez 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 When the connected system s power supply is off When the connected CPU module is reset e When a watchdog timer error occurs in the connected CPU module e
35. 1 Set online module change hot swapping 3 Cancel online module change hot swapping Replacement module 1 to 3 shows the online module change hot swapping procedure GX Developer Diagram 1 10 Online Module Change Hot Swapping of Remote I O Stations 1 14 1 2 Features OVERVIEW MELSEC TE eries Failed module OVERVIEW Standby Control system system EJ E E H g z p _ amp E a B fe J g j J A 3 2 H e EE H pg ao o i m I m n 1 Set online module Tracking cable a e change hot swapping 3 Cancel online module 2 Online module change hot swapping change hot swapping Replacement m module a lt e S 9 zZ x 2 1 to 3 shows the online module GX D
36. Point A MELSECNET H Remote I O network Point C j z EN Remote 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 O x O 2 Stations O O O x 3 Stations O O x O O Possible x Not Possible 6 23 6 2 Redundant System Network Overview 6 2 2 MELSECNET H Remote I O network REDUNDANT SYSTEM NETWORKS MELSEC TE eries 9 Operation Mode Setting for Error Occurrence For Redundant CPUs and MELSECNET H remote I O stations the operation mode for occurrence of fuse blown and module verify error can be preset in PLC RAS a gt settings in PLC parameter 2 Q parameter setting MNET 10H Remote I O station parameter PLC name PLC system PLC file PLCRAS 1 PLCRAS 2 Device Prog
37. 3 Buffer memory Table App 44 List of Buffer Memory Buffer memory address Hexadecimal decimal Stored value CH1 side 03 a P 2574 599 2674 615 Data transmission result 1 or more Abnormal completion 0 Normal completion error code Transmission data count 0 No designation 400 1024 800 2048 designation 1 or more Number of send data 401 to 5FF 8014 to OFF Transmission data Data to be sent to an external 1025 to 1535 2049 to 2559 designation device Appendix 6 9 BIDOUT Instruction APPENDICES MELSEC TE eries The program example of sending data by the bidirectional protocol communication is shown in Diagram App 34 For the I O signal is X Y80 to X Y9F i 4 4 44 444 MOV ABCDEFG MOVP HOAOD MOVP K5 TOP H8 H400 D10 SET X80 i 23 RST x81 25 FROMP H8 H257 20 RST X60 D11 D15 D10 K6 Y80 Y80 K1 Y80 32 Diagram App 34 Program Example App 53 Appendix 6 Precautions for Using Serial Communication Module Appendix 6 9 BIDOUT Instruction F Y8E Sets the send data and the number of send data Writes the send data and the number of send data to the buffer memory Turns ON the send request signal Y80 after the data is written Turns OFF the send request signal Reads the send error code Check the error description and take corrective action
38. System B Standby System System A Control System MELSECNET H Remote 1 O network Remote I O station Remote I O station Remote I O station Diagram 6 13 Overview of Remote I O Station 6 2 Redundant System Network Overview 6 2 2 MELSECNET H Remote I O network 6 REDUNDANT SYSTEM NETWORKS M als 26 FY aries 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 a gt 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 z Control system Standby system z Fag S S a E a l oI oO E B g oO Track
39. Aq collegia L Tracking cable Operating status is equalized gt Operating Status RUN 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 When both systems are powered ON simultaneously When both system CPU modules are unreset RESET L CLR switch is set to the neutral position The following stop error will occur in the control system and standby system CPU modules OPE MODE DIFF error code 6020 simultaneously When one system starts up after the other e During normal operation The following continuation error will occur in When the separate mode is changed to the backup the standby system CPU module only mode OPE 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 19 5 1 Basic Concept of Redundant System 5 1 4 System Consistency
40. 8 1 Troubleshooting Flow 8 18 8 1 6 When System Switching has failed 8 TROUBLESHOOTING MELSEC TA eries 8 1 7 When TRK INIT ERROR error code 6140 Occurred at Redundant System Startup 1 TRK INIT ERROR occurrence conditions a This error occurs when either of the following operations is performed during starting the redundant system and before the BACKUP LED turns green e Either system was powered off e The CPU module in either system was reset b This error may occur in the system using the redundant type extension base unit if extension cables are not connected and the system is not powered on as the procedures shown in Chapter 4 2 Corrective action for TRK INIT ERROR If TRK INIT ERROR has occurred during a startup of the redundant system restart the system by performing either of the following operations a Power on System A and System B again 1 When System A System B has been powered off power on System A and System B again simultaneously 2 The System A CPU module starts as a control 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 2 The System A CPU module starts as a control system
41. Tracking cable REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A GOT1000 Series GOT A900 Series CPU directly connected Remote O module MELSECNET H Remote I O network DD Serial communication module L Remote I O station Remote 1 O station REDUNDANT SYSTEM FUNCTIONS ez CAINIG W wn gt n j A Ed a Zz fa W a N x fid a E a 2 GOT1000 Series GOT1000 Series GOT A900 Series GOT A900 Series CPU directly connected Computer link connected Diagram 6 35 GOT Connection Method o z o 6 E z a O o Zz 5 35 mol Lu l a hd 6 3 Communication between the Both Systems CPU Module and GOTs 6 46 6 3 1 When connecting GOTs to MELSECNET H remote I O station 6 REDUNDANT SYSTEM NETWORKS M ELSEG Q series 2 Communication method The GOT communicates 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 modu
42. Device initial value C MAIN Clear PLC memory Format PLC memory Arrange PLC memory Create title Total tee space volume Bytes Diagram 4 12 Write to PLC Screen 2 Selection of Write Data Click the Parameters and Programs button and select parameters and programs as Write Data 3 Execution of Write to PLC Click the Execute button As the following confirmation dialog box appears click Yes MELSOFT series GX Developer N Do you want to execute writing to both systems Diagram 4 13 Execution of Write to PLC Confirmation Window 4 14 4 7 Writing Parameters and Programs to CPU PROCEDURE FOR STARTING UP A REDUNDANT SMELL M IES 26 FY aries 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 OVERVIEW 1 Powering supply ON again Power off system A and system B and then simultaneously power on the both systems CONFIGURATION SYSTEM 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 29 CPU module RESET L CLR Switch RESET __L CLR TRACKING CABLE Resetting A Unreset Diagram 4 14 Setting the CPU Module RESET Swi
43. MELSEC KE eries 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 PROCESSING TIME FOR REDUNDANT SYSTEMS 1 Device of programmable controller CPU Table App 36 Device Used in the Program Device No Application Remarks X50 Transmission command ON Transmission completion it X60 Error reset command ON Error reset a 3 lt 2 W O signal Table App 37 List of I O Signal 0 signal ARR Signal name Description CH1 side CH2 side Transmission normal Xn0 Xn7 ON Normal completion completion x EET g Transmission abnormal i z 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 ON Module error occurred Watchdog timer error X n 1 F OFF Module being normally WDT error operated Yn0 Yn7 Transmission request ON Requesting transmission 3 Buffer memory Table App 38 List of Buffer Memory Buffer memory address Hexadecimal decimal Stored value CH1 side CH2 side 0 Normal completion 2574 599 2674 615 Data transmission result 1 or more Abnormal completion error code 400p 1024 8004 2048 Transmission data count 0 No designation designation 1 or more Number of send data 4014 to 5FFy 801 to 9FFy Tr
44. Memory copy status SD1596 The system sets it i Diagram 5 91 Memory Copy Special Relay and Special Register Status 1 If any of the following malfunctions occur during memory copy from the control system to the 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 Standby system CPU reset Tracking cable disconnection or malfunction 5 119 5 7 Memory Copy From Control System To Standby System D REDUNDANT SYSTEM FUNCTIONS EJPOINT 1 MELSEC TE eries 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 SM1596 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 3D1 is set to Memory copy target I O No SD1595 and memory copy is executed the Unsupported transfer target I O No error code 42481 will be stored in SD1596 In this case memory copy will not be executed 5 7 Memory Copy From Con
45. Remote operation Connection target information Connection interface Target PLC PLC status COMI lt gt PLE module RUN System type Standby system Operation Pe sToP z Extract memory card Eee Station no Host PLC type Q25PRH Backup mode Specify execution destination Operation mode C Cunently specified station Allstations C Specific group 7 Both systems A amp B Close GX Developer Control system RUN STOP Tracking cable Standby GX Developer Remote operation Connection target information Connection interface COM1 lt gt PLC module Target PLC PLC status STOP System type Control system Operation PLC Reset z C Extract memory card Escue y Station no Host PLC type Q25PRH Backup mode Specify execution destination Operation mode Currently specified station C Allstations C Specific group Control system GX Developer 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 RUN STOP Tracking cable ft TT
46. 5 3 3 System Switching Execution Possibility 1 In Backup Mode ai System switching execution possibility in Backup Mode is shown in Table5 26 i 5 Table5 26 System Switching Execution Capability Control System Switching Condition z Automatic System Switching Manual System Switching 7 System 3 ii System ae Standby System Operating Stop Error Waktnd Switching System Switchin oZ witchi Status 1 Other Than Seren Hardware Power Off requested Switching 3 Q2 Timer Error by System Watchdog Failure Reset by the using GX Bae k 3 Switching Timer Error Network Developer i Instruction Module m Normal O Q Q O Q O O lt Continuation ERROR G O O O O O z ee Power OFF S Resetting 2 x ga OQ x x x x Hardware Failure 2 Watchdog Timer Error 2 2 x O O O x x x z Stop Error Other Than 5 x x x x re Watchdog Timer Error 7 a a 4 ube lt At network fault detection O O O O x x x R z a Or Memory Copy from Control reg System to Standby System O O O O i mea During Online Program Change O O O x x x 5 Operating Status Inconsistency O O O O x x x 2 pu Tracking Cable Disconnection x oO Oa x x x x A Preparing for Tracking x O O O x x a 22 System Switching Request Z E Timeout a O O O i 7 n 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 E 2 When the reasons for system switching failure such as standby system
47. cccococoo0000000000000000000000000000000000 5 90 Signal flow Memory eeeeseseccesecoesesecoesosocoeoooo 5 79 SM1511e seeesseesssecsoeccoocsoccsseccsoccsoocsseessecessee 5 4 SM15 1 Dececcececcccccccccccccccccccccccccccccccccesccsesess 5 4 SM15 1 Bececcccecccccccccccccccccccccccccccccccseccsccsesess 7 5 SM15QOcceeccceccccccccccccccccccccccccccccccesesesseseses 5 53 SM1501 ccecccceccccccccccccccccccccccccscccccesesesseseses 5 53 SM1 55 ececcccccccccccccccccccccccccccccccccccccccccoecs 5 112 SM15Q6eceeccccccccccccccccccccccccccccccccccccccccccecs 5 112 SM15Q 7 ececccccccccccccccccccccccccccccccccccccccccccecs 5 112 SM1 70Qeeeeccccccccccccccccccccccccccccccccccsccccsscces 5 106 SM17 1 Occeccccccccccccccccccccccccccccccccccccccsccccese 5 106 SP CONTSW instruction eocccccccccccccccccsccccceses 5 39 Special register Automatically transferred special registers 5 81 Error COMMON information esereseesereseeseeeeeesee 5 53 System switching disenabling condition s s 99 5 53 Special registers for system switchingesssessesse9e2 5 53 Special relay Automatically transferred special relays sesses 5 80 SM151 D eccocoooooocooooooooooooeoooo00000000000000000000 5 7 SM151 Gocccccoooooooooooooooo000000000000000000000000000 5 7 INDEX 2 PROCESSING TIME FOR REDUNDANT SYSTEMS n Ww Q a Z i a a lt SME6OO eoccecccccccccccccccccccccccccoccosccsccseeseeses 5 24 Standby system error detection disable flag at system swit
48. kan CC Link IE Controller Not connectable since CC Link IE Controller Network module 6 Extension base unit Network E cannot be mounted to the extension base unit MELSECNET H PLC to Not connectable since MELSECNET H module cannot be mounted a PLC network x to the extension base unit gt MELSECNET 10 PLC Not connectable since MELSECNET H module cannot be mounted z Q to PLC network i to the extension base unit z CC Link connection O miN KZ Bus Connection x CPU Direct Connection O MELSECNET H remote z MK I O station omputeriin O Ak Connection g Ethernet connection O m o Z Bus Connection x is 2 oS MELSECNET 10 remote CPU Direct Connection x Not connectable since MELSECNET 10 is not compatible with the eS I O station Computer Link Redundant CPU F x Connection Applicable x N A a 1 EXTEND BASE ERR error code 2012 occurs to the CPU module whose first 5 digits of serial 2 No is 09012 or later tt 5 5 oO 6 3 Communication between the Both Systems CPU Module and GOTs 6 44 6 REDUNDANT SYSTEM NETWORKS M ELSEG Q series GOT1000 Series GOT A900 Series Ethernet connection Personal computer Ethernet CC Link IE Controller Network GOT1000 Series GOT1000 Series GOT A900 Series GOT A900 Series QCPU GOT1000 Series CC Link IE Controller CPU directly connected CPU directly connected
49. o e o zZ O O ol w l D 2 O hA 8 1 Troubleshooting Flow 8 1 2 When the CPU Module BACKUP LED is ON Red 8 TROUBLESHOOTING MELSEC TE eries 2 3 Replace control system s CPU module 1 lt gt gt Section 8 3 Clear the control system CPU module errors 3 Section 8 2 Is the BACKUP LED lit up solid green YES Please contact the nearest Mitsubishi represenative reseller or branch office and explain the fault symptoms Completed Diagram 8 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 Make sure to check the control system BACKUP LED after replacing the CPU module 2 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 8 1 Troubleshooting Flow 8 1 2 When the CPU Module BACKUP LED is ON Red TROUBLESHOOTING MELSEC KE eries 8 1 3 When the SYSTEM A B LED is flashing The following flow Diagram 8 5 is for the case where the control system CPU module ai SYSTEM A B LED is flashing while the redundant system is running i 6 The SYSTEM A B LED is flashing O E Has
50. CONFIGURATION SYSTEM MELSECNET H module NO TRACKING CABLE Are the station numbers with pairing settings serial numbers Are parameters of the PLC to PLC network no settings when the station number is 0 REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Are parameters of the remote master station no settings when the station number is other than 0 REDUNDANT SYSTEM FUNCTIONS Correct the module type or station number YES REDUNDANT SYSTEM NETWORKS NO Are all parameter Rewrite the network parameters contents normal YES A hardware failure occurs to the CPU module Consult your local Mitsubishi representative explaining a detailed description of the problem PROGRAMMING CAUTIONS o e Diagram 8 15 Flowchart for when LINK PARA ERROR Occurs o zZ O O ol w l D 2 O hA 8 1 Troubleshooting Flow 8 28 8 1 14 When LINK PARA ERROR Occurs 8 TROUBLESHOOTING 8 29 MELSEC TA eries 8 1 15 When SP UNIT VER ERR Occurs The following shows the flowchart for when SP UNIT VER ERR occurs during operation of the redundant system An error message SP UNIT VER ERR was detected Is CC Link IE Controller Network module of function version D used NO YES Is MELSECNET H module of No function version D used YES NO Is Ethernet module of function version D used
51. STOP Reset t STOP J standby system Tracking cable Diagram 5 106 Remote Reset Operation after Execution of Remote STOP for Control System or Standby System CPU Module from 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 10 Redundant CPU Functions Restricted in Redundant System 5 10 2 Remote Operation for Redundant System 5 138 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol ii E v gt a z lt fa zZ 5 fal w ind o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series 5 11 Access to Module Mounted on Extension Base Unit Table5 65 shows the access to a module mounted on the extension base unit when accessing from the control system and when accessing from the standby system Table5 65 Access to Module Mounted on Extension Base Unit It Execution N Access from control system Access from standby system em ame timing Backup mode Separate mode Backup mode Separate mode At END Input from input module Execute Ex
52. i Tracking cable TRACKING CABLE GX Developer Remote operation Connection target information REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Connection interface COM1 lt gt PLC module RUN gt STOP RUN Target PLC J Station no Host PLC type 025PAH Control system Standby system PLC status RUN a nooo ooo ooo000 ooo System type Control system Operation mode Backup mode Bj Jeee E FI 7 A Operation Specify execution destination J J PLC Currently specified station E J3 El o a D A C Extract memory card corani 5 J e 5 fe E A Specific group S r Z C Both systems A amp B Tracking cable 6 2 a az w gt are GX Developer Diagram 5 99 Remote STOP Operation When Current Station Is Specified A 5 ip Ze om zO Be W Ww rz 9 zZ o 6 z2 ao 9 zZ fe E N W l a 5 10 Redundant CPU Functions Restricted in Redundant System 5 132 Z 5 10 2 Remote Operation for Redundant System D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries b Remote operation for both systems When Both systems A amp B is selected at the execution destination area on the Remo
53. 8 TROUBLESHOOTING Is error code 2012 YES Is GOT connected to main base unit via bus connection Does Q65WRB exit Is the first extension stage Q65WRB Are the number of slots the same between main base units of control system and standby system NO Is Q4 base connected MELSEC TE eries Remove bus connection cable connected to main base unit Use Q65WRB in the first extension stage Use the same model of main base unit in both systems A and B Remove 4 base and replace with redundant power extension base unit Is Q5LB extension base unit incompatible with power supply module connected s Check serial No of CPU module by system monitor of GX Developer Remove Q50B and replace with redundant power extension base unit Is first 5 digits of serial No of NO CPU module 09012 or later Is error code 2013 Hardware failure of the following modules is suspected 8 23 CPU module may have hardware failure Consult your local Mitsubishi representative explaining a detailed description of the problem Extension base unit Extension cable Consult your local Mitsubishi representative explaining a detailed description of the problem Replace with CPU module compatible with extension base unit Diagram 8 11 Flowchart for when BASE LAY ERROR Occurs
54. BIDOUT Instruction EE ee AD 52 BIDIN Tals ta 010 th ey ADD 54 Cautions on Communications Made via Module on Extension Base Unit seeeeeeeeeesees0 Ann 55 INDEX 1 to INDEX 3 ABOUT MANUALS The following manuals are also related to this product In necessary order them by quoting the details in the tables below Related Manuals 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 cables memory cards and others Sold separately Qn H QnPH QnPRHCPU User s Manual Function Explanation Program Fundamentals This manual explains the functions programming methods devices necessary to create programs with the QCPU Sold separately MELSEC Q L Programming Manual Common Instruction This manual describes how to use the sequence instructions and application instructions Sold separately MELSEC Q L QnA Programming Manual PID Control Instructions This manual describes the dedicated instructions used to exercise PID control Sold separately MELSEC Q L QnA Programming Manual SFC This manual explains the system configuration performance specifications functions programming debugging error codes and others of MELSAP3 Sold separately MELSEC Q L Programming Manual MELSAP L This manual describes the programming methods specifications functions and so on that are necessary to cre
55. C Start with Debug mode Backup mode setting IV Check operating status consistency Default 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 System A Control System System B Standby System Control using Initial start mode i Tracking cable Power the system off and back on System A Control System System B Standby System oooo00 ooo000 Control using Initial start mode IGAC o Tracking cable D100 D101 Diagram 5 18 Initial Start Mode Operation 5 29 5 1 Basic Concept of Redundant System 5 1 6 Start Mode D REDUNDANT SYSTEM FUNCTIONS MELSEC KE eries
56. Flow for the Case where the MODE LED is not ONeesecesecccccccccccccccccccccccccccsccccscsoceesee 3 A When the CPU Module BACKUP LED is ON Red s eeeeeeeesesseececesocsocecocooooocecocooosoeeee 8 5 When the SYSTEM A B LED is flashing eeeeeeeseeseeesecesosocececcoooococecoeoooccceccoooososeeee 8 B When the System A System B CPU module RUN LED is not ONesseeseeseescesecccccccccscoses 3 10 When System Switching has Occurred serresscsecscccececcecsccsccccccccescccccccccccesesccccssceeesees B 12 When System Switching has failed e seeeeeeeeseseeeeeeecescocecceoeoooocccecooooocececoeooosoeecoeoeooe B 14 When TRK INIT ERROR error code 6140 Occurred at Redundant System Startup 8 19 When CONTROL SYS DOWN error code 6310 to 6312 Occurred at Redundant System Startup eeeeeeeesessecesesceseosecocsoccocoscccccsoccoccoscccooscocossseccooscossssccsosccossssocsosssoossseessoe 3 20 When ETX CABLE ERR OCCUrS esseesseeessecseeessecssoocsocccoccssecssoecosoccocesseessoecsoossoee B 21 When BASE LAY ERROR Occurs esseeseeessseeseeecooecooessoesocccsocccoocssoessecsooecsoocsoessoe B 22 When UNIT LAY DIFF Occurs s eesseeesseesseecocesceccsooccooccsoecocecsoeccocessoesocecssoecooessee B 24 When SP UNIT DOWN OCCuUrs seesseeesseecseccseesseccsoeccoocococsocecsoeccocccsoesocecsoeccoocsooe B 25 When SP UNIT LAY ERROR Occurs seessseeseesseeesceccsoeccooccocesceccsoeccoocsocesssecsoeesooe 3 IG When LINK PARA
57. Gol coll le s CAI 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 simultaneously The following stop error occurs 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 CARD TYPE DIFF error code 6040 or 6041 position simultaneously If the CARD TYPE DIFF error occurs in the control system and standby system CPU modules set the same memory card in each system 5 23 5 1 Basic Concept of Redundant System 5 1 4 System Consistency Check D REDUNDANT SYSTEM FUNCTIONS EJPOINT 4 MELSEC KE eries 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 t
58. J Sets frame No to be registered Sets the number of data byte to be registered Sets registered data of a frame to be registered to D4 to D8 Sets the write permission to the flash ROM Registers user registration frame Sets the flash ROM write request flag Writes data to the flash ROM Reads registration result when write completion is turned ON Executes error processing when D2 is other than 0 Resets the flash ROM write request flag APPENDICES MELSEC KE eries Appendix 6 5 GETE Instruction The following shows the device and buffer memory used in the sample program of reading the user registration frame PROCESSING TIME FOR REDUNDANT SYSTEMS 1 Device of programmable controller CPU Table App 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 APPENDICES 2 W O signal Table App 31 List of I O Signal VO signal 2 R Signal name Description CH1 side CH2 side X n 1 7 Flash ROM read completion ON Completed il Q Y n 1 7 Flash ROM read request ON Requesting zZ X n 1 E Q series C24 ready ON Accessible ON Module error occurred Watchdog timer error X n 1 F OFF Module being normally WDT error operated 3 Buffer memory Table App 32 List of Buffer Memory Buffer memory address Hexadecimal decimal CH1 side C
59. MODEL 13JR76 SH NA 080486ENG O 1106 MEE afa MITSUBISHI ELECTRIC CORPORATION HEAD OFFICE TOKYO BUILDING 2 7 3 MARUNOUCHI CHIYODA KU TOKYO 100 8310 JAPAN NAGOYA WORKS 1 14 YADA MINAMI 5 CHOME HIGASHI KU NAGOYA JAPAN When exported from Japan this manual does not require application to the Ministry of Economy Trade and Industry for service transaction permission Specifications subject to change without notice
60. YES Check operation starting from a minimum system For modules that do not operate consult your local Mitsubishi representative explaining a detailed description of the problem Use CC Link IE Controller Network module of function version D Use MELSECNET H module of function version D Use Ethernet module of function version D Diagram 8 16 Flowchart for when SP UNIT VER ERR Occurs 8 1 Troubleshooting Flow 8 1 15 When SP UNIT VER ERR Occurs 8 TROUBLESHOOTING M eLS 26 Fel ceries 8 1 16 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 CC Link IE Controller Network or MELSECNET H OVERVIEW 1 Cause of CAN T SWITCH occurrence In the redundant system where CC Link IE Controller Network or MELSECNET H is used CC Link IE Controller Network or 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 CC Link IE Controller Network interface board or MELSECNET H board is mounted For details of function requesting to switch system to the control system CPU module refer to the following manuals lt gt CC Link IE Controller Network Reference Manual L gt
61. f 1 Initial setting program for Q series C24 N i Pee Da TOP H8 H96 K1 K1 Writing is not required when send L data is set in units of bytes words X50 8 PLS MO J Pulse outputs send command MO 11 MOV H1234 DO MOV H5678 D1 gt Sets send data TO H8 HOCOO DO K2 7 J Sets the buffer memory head MOV HOCOO D2 i address where the send data is stored and the data length z a Program MOV K2 D3 MOV K4 D3 j J when send data is set in units of words Sets the on demand buffer memory TO H8 HOAO D2 K2 Jhead address data length SET M1 Turns ON the on demand data set flag M1 X9E X9F X80 X81 X82 Y80 31 Hhh RST Y20 Resets output signal for z checking operator RST Y21 SET Y80 Starts up the on demand send request RST M1 Turns OFF the on demand data set flag Y80 X80 E dl 42 LSET Y20 Completed normally X81 A l SET Y21 J Failed Reads LED status and on demand FROM H8 H256 D4 K1 execution result and checks the p cause of error completion 2 _ Address 256 FROM H8 H201 D5 K1 Jio Data sent normally Other than 0 Data not sent normally due X80 to error occurrence 59 RST Y80 Cancels send request X81 X60 J 62 TO H8 HO HOFF K1 Requests turning OFF error LED Y8E Resets stored value of on demand execution result Diagram App 31 Program Example App 47 Appendix 6 Precautions for Using Serial Communication Module Appendix 6 6 ONDEMAND Instruction APPENDICES
62. m T J J a CPU1 x O Ss 4 3 ale H a gE CPU2 x O ia m 3 k O z CPU3 x O 6 53 Tracking cable O Applicable x Inapplicable Diagram 6 40 System Configuration for Communication from Other Networks with Control System Specified 6 4 Precautions for Accessing Redundant CPU from Other Networks 6 REDUNDANT SYSTEM NETWORKS M als 26 fel ceries 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 3 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 5 to the standby system CPU module Ei e Control system power off 8 e Control system CPU module reset e Control system hardware fault e Control system CPU module stop error m At this time the new control system CPU module after system switching uses the old device data for control z O ke 2 Checking for system switching after device data write After writing device data to the control s
63. 1 Network Module Redundant Group Settings When a pair of Ethernet modules is used in each system 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 Diagram 5 92 and Diagram 5 93 show the operations when an error occurs in the communication between the control system and standby system via the Ethernet e Diagram 5 92 show the processes that take place when a malfunction occurs on one of the networks with network module redundant group settings E a I OPS OPS OPS Control system Comms Standby system Control system Comma Standby system System A av System B System A a System B a S E g J gt El E a l 3 3 el ee Tracking cable Systems did not switch Diagram 5 92 Operation When Error Occurs on One of the Networks Tracking cable One of the modules set in the redundant group setting has request
64. 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
65. 33 35 33 83 33 35 53 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 2 Features 1 OVERVIEW MELS eG el series 5 Writing parameters and programs to control system and standby system without the need to identify each system Parameters and programs can be written into both of control system and standby system using GX Developer There is no need to identify each system C7 Section 5 6 1 Control system 2 f ma le Standby system ima le nooo ooo000 ooo000 ICO TC ola 1 Execute PLC Write 2 Write to Control system GX Developer 3 Write to Standby system Diagram 1 7 Writing to the Control System and Standby System by Download to PLC 1 2 Features 1 to 3 denotes the process up to writing OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING
66. 5 3 The System Switching Function 5 54 5 3 5 Special Relays Registers For System Switching OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Sa Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG Q series Table5 39 Special Registers For System Switching Continued Setting at Time of System Switching New Control System New Standby CPU Module System CPU Module Device No Description e 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 b1 b0 0 OFF 0 Fixed 1 ON SD1600 re cable loose or damaged Powered down reset watchdog timer hardware fault in the other system Other system stop error sb1600 System Fault excluding watchdog timer O O Information error 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 e If one of b0 b1 b2 and b15 turns ON the others will turn OFF In Debug Mode bO b1 b2 and b15 are all OFF Stores system switching conditi
67. Holds the data Sets the received tracking data in the signal flow memory Does not process it 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 settings 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 FROM TO 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 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 satisfied Not pr
68. Q Corresponding MELSECNET H Network System Reference Manual PLC to PLC network L gt Q 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 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS o e o zZ O O ol w l D 2 O hA 8 1 Troubleshooting Flow 8 30 8 1 16 When CAN T SWITCH Occurs to Control System CPU Module due to Communication Error when 8 TROUBLESHOOTING M100 oO 8 31 MELSEC TA eries 2 How to cancel CAN T SWITCH 3 Cancel CAN T SWITCH detected by the control system CPU module after checking that the standby system and the CC Link IE Controller Network module or 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 17 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 S
69. TRACKING CABLE PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 2 1 System Configuration 2 a7 2 SYSTEM CONFIGURATION MELSEC TE eries 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 6 for modules on a remote I O station that can be replaced online hot swapping using GX Developer Mutiplexed Remote Master Station Mutiplexed Remote Sub master Station System A System B 2 p Cats System Q35B Standby System a3sB _ C 1 Intelli refers to the Intelligent Function module 2 In a coaxial bus system use double shielded coaxial cables Refer to the following manual for the double shielded coaxial cables Q Corresponding MELSECNET H Network System Reference Manual Remote I O network QnPRHCPU QJ71LP21 QJ61BT11N QJ71E71 QnPRHCPU QJ71LP21 QJ61BT11N QJ71E71 QJ71GP21 SX QJ71GP21 SX 2 2 3 E 3 3 o e E E a a 2 2 5 3 D a i 2 3 6 a a a al Tracking cable MELSECNET H Remote I O network Redundantly powered Q33B Remote I O station a x amp 6 QJ72LP25 QJ72LP25 Q64RP QJ72LP25 Input module Input module Input module Input module Input module Input
70. a W X o Z O O Z Le REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q 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 System System Standby System Operating Stop Error TORR Switching System A ni x witchin Status 1 Other Than i plate Hardware Power OFF requested Switching 5 g Timer Error g with System Watchdog Failure Reset by the Using GX ee 7 Switching Timer Errors Network Developer Instruction Module Normal x x x x x O O Continuation Error x x x x x O O Power OFF Resetting x x x x x x x Hardware Failure Watchdog Timer Error 2 x x x x x x x Stop Error Other Than Watchdog Timer Errors i z a i 5 At network fault detection x x x X x O D Copying memory from Control System to Standby System x x i i a mn During Online Program Change x x x x x Q O Operating Status Inconsistency x x x x x O O Tracking Cable Disconnection x x x x x x x Preparing for Tracking x x x x x x x System Switching Request 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 i
71. 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 CC Link IE Controller Network module MELSECNET H module dedicated instruction e Remote operation by MC protocol e Remote operation function from OPS using EZSocket 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 2 Remote reset can be executed for only the control system CPU module Performing remote reset for the control system CPU module resets both systems b In the separate mode Remote operation can be performed for only the CPU module of the system specified in the Connection Setup of GX Developer or other means 2 Target Specification for Remote Operation As the target CPU module of remote RUN remote STOP remote PAUSE or remote latch clear select the CPU module of either system or the CPU modules of both systems in the Connection Setup of GX Developer Remote operation Connection target information Connection interface COM1 lt gt PLC module Target PLC gt Stationno Host PLCtype Q25PRH PLC status UN Select when performing System type Eontotaystem Operasion mode Backup mode remote operation f
72. e To communicate via a module mounted on the extension base unit by using MC protocol use QnA compatible 2C 3C 4C frame QnA compatible 3E frame or 4E frame for the access e 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 OVERVIEW N L gt GX Developer Version 8 Operating Manual L gt PX Developer Version 1 Operating Manual Programming Tool ES POINT Only the control system can access modules on the extension base units If accessing the standby system while the system monitor function of GX Developer is in execution the extension base units and modules on them are not displayed Using GX Developer with specifying Control system at Target system in the Transfer Setup screen is preferable z O T 5 o Le Z Q SYSTEM TRACKING CABLE 2 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 station or extension base unit Remote I O station remote device station and intelligent device station can be used by mounting CC Link master module on a main
73. eeeeecceseseccccoccoccoccoccococccosocococccoccoesooooooo 6 1 Confirming the Connection Target on GX Developer coooooooooooooooo00000000000000000000000000000000 N 3 Cautions on Access from GX Developer and PX Developer eseseeeeesseeeeesecooececoooocoooooo000 6 4 6 2 Redundant System Network Overview coooooooooooooooo00000000000000000000000000000000000000000000000000000000 7 6 2 1 6 2 2 6 2 3 6 2 4 6 2 5 6 2 6 CC Link IE Controller Network or MELSECNET H PLC to PLC network eccccecccccccccccccccceeee G Q MELSECNET H Remote I O network SOCOHSHSHSHSHSSHSHSSHSHSHSHSHSHHSHSHSHSHHSHSHSHSHSHHSSHSHHSHSHHSHSHHHOHHHSHHOHHHOHOOOEES 6 17 Ethernet CO COCOOOO OOO OOOO OOO OOOO OOOOH OOO OOOO OOOOH OOOOH OOOO OOO OOOOH OOOO OOO OOO OOOO OOOO OOO OS OOOO OOO OOOO OOOO OOOOOOE 6 26 CC Link ssesssccccoco000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 6 30 Serial Communication Modules COCO OOOOO OO OOO OOOO OOO OOOO OOOO OOOO OOO OOOO OOO OOOO OOOO OOO OOOO OOO OOO OOOO OOOOE 6 37 PROFIBUS DP CO COCOO OOOO OOO OOOO OOO OOOO OOO OOOOH OOOO OOO OO OOOO OOOO OOOO OOOOH OO OOO OOOO OOO OOOO OOO OO OOOO OOOOOOOCS 6 42 6 3 Communication between the Both Systems CPU Module and GOTS eeeseeseeseesecscccesccsccscoseese G 44 6 3 1 6 3 2 6 3 3 6 3 4 When connecting GOTs to MELSECNET H remote I O stationsssesseesescccccscccccsccccccccceees G 46 When Connecting GOTs to CC Link eeeeeeeses
74. 26 nO System A Control System System B Standby System Vine Le SEs h ae LE J f migs l j w a d El p H E NB AL IC z o S Tracking cable A 5 CC Link Remote I O station station No 2 a x p Zaa woe 204 i i aes Master station operation standby Standby masier Station operation ORS master station operation Station No 0 gt master station operauon z m Station No 1 anr System A System B Control System Standby System bf og o a i El Elora 2 a al 5 il i i emote gt ll al Ee ll F SH 2 SIF E ONS ay ig SF lal zg gO Tracking cable 55 az W D ew 6 Remote O station ii station No 2 7 Diagram 6 24 CC Link Operation at System Switching z x 2 POINT Auto refresh can be made when mounting the CC Link master module to the extension base unit Set the tracking device setting to the device where the auto 3 refresh is performed 7 When using the auto refresh set Refresh settings of the network parameter g Set the tracking device setting to the device where the auto refresh is set g3 z o 2 i 3 fe 6 2 Redundant System Network Overview 6 30 6 2 4 CC Link 6 REDUNDANT SYSTEM NETWORKS M ELSEG Q series 1 Overview of Remote Stations In a redundant 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 da
75. 4100 will occur PROCESSING TIME FOR REDUNDANT SYSTEMS APPENDICES INDEX Appendix 5 Method for Starting up the Previous Control System App 28 APPENDICES MELSEC LAY ceries 2 When network module is mounted Make sure that the network module has started up and then create a program that executes the SP CONTSW instruction a CC Link IE Controller Network module MELSECNET H module or Ethernet module is mounted on the main base unit System Configuration System A System B a p 5 Tracking cable Diagram App 19 System configuration when CC Link IE Controller Network module MELSECNET H module or Ethernet module is mounted on the main base unit Program Example SM1519 0 T CALL P100 Makes the subroutine program P100 execute when the previous control system is the system B GOEND j Jumps the processing to the END instruction by executing the system switching instruction r i 4n User program H ite a E i EE em a rama i E E 4 6 FEND Ends the main routine program P100 7 SMIS r Stores the value of SD412 at subroutine program 1 LMOVP SD412 D400 T 3 execution to D400 Lf SD1690 HO j SET sM1592 H Enables system switching when the network module in
76. Ascending x Error message Year Month Day Fie save Error message it File save CONTROL EXE 2008 3 18 16 38 12 a STANDBY 20 8 Error Jump Error Jump Help Boe Lu P Diagram 5 20 New Control System PLC Health Check Diagram 5 21 New Standby System PLC Health Check a a E Display Display E mA 2 If the WTD error occurs in the new standby system PLC diagnostics cannot be done via the 3 g a tracking cable Tbe 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 ol The reason for system switching can be confirmed on the Error details window Error details Common error information Individual error information Reason s for system switching Lu E wn gt wn i Zz lt x a rs D2 a W ao o Z O O Z Le ees leert noting 0 No system switching condition default Rescon for sytem 1 1 Power OFF reset hardware failure watchdog timer error 2 Stop error except watchdog timer error 3 System switching request by network module o 16 Control system switching instruction 2 a cA 17 Control system switching request from ae zO GX Developer 2s a W Ww rz Diagram 5 22 Error details window e zZ o 56 z2 ao f0 zZ e 25 N W a 5 3 The System Switching Function 5 34 5 3 1 System Switching Method D REDUNDANT SYSTEM FUNCTIONS MELSEC
77. BOOT LED is also flashing 8 TROUBLESHOOTING MELSEC KE eries 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 2 4 USER LED Ww Off Normal f6 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 2 On Boot operation has started 5 Off Boot operation has not been executed Be 6 BOOT LED f oe f F ao 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 m On Red Unable to continue the control RUN because of system switching 5 On Amber Separate mode z Off Debug mode z 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 z Control system Standby system Control system Standby system R a 7 Indicates the system of the CPU module i e control system or standby system On Control system System switching is possible as the standby system is 8 CONTROL LED ai normal Debug mode Off Standby system E Indicates the system A CPU module status 36 On Operating as system A AZ Debug mode ate Flashing Th
78. CPU module em REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Control system Standby syst Col lCole est 1Cot REDUNDANT SYSTEM FUNCTIONS Tracking cable Replace after turning OFF the standby system power GX Developer Diagram 8 20 System where Standby System CPU Module is Replaced REDUNDANT SYSTEM NETWORKS 2 Replacement Procedure The procedure for replacing the CPU module is shown in Diagram 8 21 Confirming the System of the Replacement Target CPU Module Confirm that system of the target CPU module is the standby system the CONTROL LED is off When replacing the control system CPU module switch its system to the standby system using PROGRAMMING CAUTIONS GX Developer o e Refer to Section 8 3 1 for system switching using GX Developer Power OFF the Standby System o zZ O O ol w l D 2 O hA 8 3 Replacing Module in Redundant System 8 36 8 3 1 CPU Module Replacement 8 TROUBLESHOOTING 8 37 Disconnecting the Tracking Cable Disconnect the tracking cable from the standby system CPU module Refer to Section 3 3 for disconnecting the tracking cable Replacing the Standby System CPU Module 1 Remove the sta
79. Confirming the serial No on the system monitor Product Information List To display the System monitor screen select Diagnostics System monitor and click the Product Information List button in 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 sot Type series model name Points 1 0 wo waster PLC Q Q25PRH 060510000000000 D PLC Q QJ71LP21 25 32pt 0000 060510000000000 D None Diagram 2 12 System Monitor Product Information List POINT The serial number displayed on the Product information list screen of GX Developer may differ from that on the rating plate and on the front of the module 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 M aL 26 fel ceries 3 Available software packages a Available GX Developer and PX Developer versions OVERVIEW Table2 2 shows GX Developer and PX Developer versions supporting redundant system N Table2 2 Available GX Developer and PX Developer versions Ver 8 17T or later 1 3 Ver 1 05F
80. ERROR Occurs e esseeesseeseessseesscecsoeccoocssecssoecsocccocessecssoecsoessooe B 27 When SP UNIT VER ERR OCCurg esseeesseeseeesseescceccooccoccssoessoeccooccooesssecsseccooessoe B 29 A 13 8 1 16 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 CC Link IE Controller Network or MELSECNET H eeeeeeeeeesesecsscecosoooooeooooee 8 ZQ 8 2 Error Clear scccccccoooooooo0000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 8 32 8 3 Replacing Module in Redundant SyStermecececcccccccccccccccccccsccccccscccvccscccsocscccsoosccccsooscoccocs 8 36 8 3 1 8 3 2 8 3 3 8 3 4 8 3 5 8 3 6 8 3 7 8 3 8 8 3 9 8 3 10 CHAPTERS PROCESSING TIME FOR REDUNDANT SYSTEMS CPU Module Replacement eseeeseseeseeseccssscecosesocososocooscocoossocosoccosossccsosccossssoesossee 3 3G Power Supply Module Replacement Procedure eeeeeeseseeeeececeoosececocooooceccocoosoosececoeoeo B 38 Redundant Power Supply Replacement Procedure s eeeeseeeeeeeececsosececcecooeceecoeoosseeeeeeoo B 40 I O Module Replacement Procedure eeeeeseeesseeecesesocosseccoocccocooseososscoossseesosscocssseesoe 3 41 Network Module Replacement Procedure sseesesesessesessececcsesocsscccccossocossccossssosseseosoe 8 43 Main Base Unit Replacement Procedure eeseeeseeeseseesesesececossoccosscocoscocossceosossoess
81. For details refer to each network manual 5 If the RUN STOP switch of standby CPU module is set to RUN and the operation status differs between the control system and standby system the consistency check causes OPE MODE DIFF error code 6010 in the control system CPU module gt Section 5 1 4 Lu wn gt wn p FA Ed m Zz a W a S 2 lt ws a2 S a REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 4 3 4 4 4 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM 2 Procedure for starting up in debug mode M ELSEG seres The standard procedure for starting up either system in the debug mode is shown below Explanation of program and parameter creation is not provided here l Mounting Modules Mount the power supply module CPU module network module and I O module to the main base unit extension base unit 1 Connect the power cable to the power supply module 2 Connect the battery connector to the CPU module battery connector 3 When connecting the extension base unit connect the main base unit and the extension base unit by an extension cable 4 Connect the network wiring to the network module 1 5 Connect the I O module Module Initial Settings 1 Set the RUN STOP switch of the CPU module to the STOP position 2 Set the RESET L CLR switch of the CPU module to the reset switch ne
82. Hardware Design Maintenance and Inspection 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 Standby System LED common to System A System B i e Control CPU Module LED System Standby System Q12PRHCPU Control Standby MODE BACKUP LED Name System System RUN CONTROL ERR SYSTEMA System A System B USER ISYSTEM 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 O ij gt Diagram 4 15 CPU Module RUN STOP Switch Position and Setting 4 16 4 9 Error Check MELSEC TE eries 4 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM Memo MalAY3AO NOLLVYENSISNOO WALSAS gaY ONIMOVeL z WALSAS LNYANNAAY V dN ONILYVLS YOs JYNAIDOYd SNOLLONNA WALSAS LNYANNAAY SMYOMLAN W3LSAS LNYANNAAY SNOILNVO O NINWYH9O0 d SONILOOHSSTENOdL N 4 1 4 11 Running CPU Modules D REDUNDANT SYSTEM FUNCTIONS MELSEC TA eries CHAPTERS REDUNDANT SYSTEM FUNCTIONS This chapter explains the redundant system functions 5 1 Basic Concept of Redundant
83. However in the separate mode system switching is not executed even if a fault or failure occurs in the control system System switching can be manually carried out Debug mode The debug mode is for debugging with a system configuration of only either system prior to the system operation In a redundant system two Redundant CPUs are normally required however debugging can be executed with only one CPU In the debug mode the CPU module uses the parameters for system A to operate Therefore the station set as system B in the network parameters becomes absent station disconnected station Check the system switching operation in the backup mode prior to the system operation because the system switching cannot be checked in the debug mode On the programming at system switching refer to CHAPTER 7 PROGRAMMING CAUTIONS 5 1 Basic Concept of Redundant System 5 2 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries 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 as System A and the other System B System A and System B are determined by the direction of the tracki
84. Memory copy precautions evcccccccccccccccccososose 5 443 Module initial SEttINGS eoreececccccccccccscccsccscccccsees 4 12 CPU module RESET L CLR switch settings 4 12 CPU module RUN STOP switch settings s s 4 12 Modules applicable to redundant system seeseseee 2 13 Mounting MOIUIES ecececccccccccccccccccccccccccccccccces AG N Network module s sssscccocooc00000000000000000000000 2 20 New control system cooocoooooooooooooooooooo00000000000 77 New standby system Cocccccccccccccccccccccccccccoccccs 1 22 0 Operating status consistency check settings 5 20 Operation MOE eecccccccccccccccccccccccccccccecccccccoss H Q Backup MOE 0000000000000000000000000000000000000000 5 O Debug MOE eccceccccccccccccccccccccccccccccccccocces D 13 Separate MOE ecececcccccccccccccccccccccccccccccccce 5 1 Operation mode change cooooooooooooooo00000000000000 5 58 Operation mode change procedure seseeseeseseeeee9 5 58 Operation status consistency check eseesesseseeeeee 5 19 Operations when changing operation mode 5 63 Other system diagnostic error eeeeeseeeeeeseseeo000 5 55 Overview COCCOOOOCO OOO OO OOOOH OOOO OOOO OOOO OOO OOOO OOO OOOOOCE 1 1 P Pairing Settings and relevant CPU modules sess 2 5 Parameter valid drive settings consistency check eoccccccccccccccccsccccccccccccccccccscccccceccccccccsseccoes 5 D5 Peripheral device Configuration seesesseeseseeseeseese 2 12 PID Control instruction data eeeeeesseeeeessse
85. Network type Group settings E When module No 3 is z set in Group module 5 3 ooo _ Ethemet Manbase No 3 becomes crouped mn group S 4 ooo Ethernet Main base with module No 4 i a nZ S 58 E e a an Em E 11 Lu q S Diagram 5 94 Network module redundant group setting Screen S 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 1 fi oe b15 to b11 to b1 bO iF a sp1590 o Jon Zz on o Sox A aes Module 0 CPU module is invalid as it is 2 slot module 3 z a EGE Module 1 Module on the right side of CPU module to Module 11 Module at right most end of 12 slot base Q312B ol Diagram 5 95 Network Module That Issued System Switching Request 41 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 Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le E Module No 11 Slot 11 5 5a gz 4 When a non redundant network module is set in the redundant group E settings rz If redundant group settings are made for a network module that does not support redundant systems a stop error PARAMETER ERROR error code 3000 will occur 7 In this case check the network parameter group settings 2 2 Q i 3 E 5 9 Network Module Redundant Gr
86. PRC Print Comments S P SFCF Request of Motion SFC Program Startup KEY Numerical Key Input S P SVST Request of Servo Program Startup 2 Axis Speed Change during Positioning and JOG 2 UDCNT1 1 phase Input Up Down Counter D P CHGV j Z operation w Q Torque Control Value Change during Operation and lt UDCNT2 2 phase Input Up Down Counter D P CHGT ie Suspension in Real Mode Current value Change of Halted Axis Synchronized TTMR Teaching Timer D P CHGA Encoder Cam axis STMR Special Timer D P DDWR __ Write Other CPU Device Data into Host CPU ROTC Rotary Table Near Path Rotation Control D P DDRD Reads other CPU device data into the host CPU RAMP Ramp Signal x D P GINT Request of Other CPU Interrupt Program Startup f SPD Pulse Density Measurement S Table App 5 Instructions Restricted for QnPRHCPU Instruction Symbol COM Selection Refresh n For restrictions on COM and ZCOM refer to Section 7 1 7 ZCOM Refresh of Specified Module f Instruction Name Remark Appendix 2 Comparison of Qn H CPU and QnPRHCPU App 8 APPENDICES MELSEC Le ceries Appendix 3 Comparison of QNPHCPU and QnPRHCPU A comparison of QNPHCPU 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 Sevan Sean Time Internal device 48 k word setting time Pane e Synchronized tracking mode 41 ms Program priority mode 21 ms
87. Set 141 to be valid Step 0 to 11 Forcibly change the system that communicates with the CC Link APPENDICES Step 47 to 49 IRET Initialize devices at the time of system switching Step 12 to 14 Refresh the remote devices and enable system switching Step 15 to 35 INDEX Refresh the CC Link Step 36 to 45 FEND Diagram App 6 Sample program overview flow Appendix 4 Sample Programs when Using CC Link App 20 Appendix 4 5 Sample Program APPENDICES 2 Sample Program SM402 0 FMOV HOFFFF D100 SM1518 MOV H200 IMASK SM1518 RST RST M100 U4 BMOV K4Y1000 G352 U4 BMOV G224 K4X1000 U4 BMOV W1100 G480 U4 BMOV G736 W1000 SB45A SB45B KS i ET SB442 B443 RST KO SW443 eR __ _ _ SET Diagram App 7 A sample program of CHANGE App 21 Appendix 4 Sample Programs when Using CC Link Appendix 4 5 Sample Program K8 D102 DI D100 El SB40C M100 K10 K10 K20 K20 B401 B401 M100 FEND SB40C IRET MELSEC TE eries Adds 141 to the allowable interrupt r defaults 10 to 131 148 to 1255 Set CC Link forced master switching flag to OFF Set control program execution flag to OFF Performs a refresh of RY Y1000 to Y109F Performs a refresh of RX X1000 to X109F Performs a refresh of RWw W1100 to W1113 Performs a refresh of RWr W1000 to W1013 Set refresh update request
88. application using EZ Socket too 5 33 5 3 The System Switching Function 5 3 1 System Switching Method REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries 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 i In this case the ERR LED will remain off The ERR LED does not turn on or flash te gt e New control system CONTROL EXE error code 6200 O 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 2 z PLC diagnostics PLC diagnostics T ai PLC status PLC status ao PLC operation status PLC operation status Reo PLC operation RUN switch RUN Tracking connecting PLC operation RUN switch RUN Tracking connecting QS Connective system Control system System B Backup mode Manual switching Enable Connective system Standby system System A Backup mode Manual switching Enable nO rey Ene Monitor run stop Pesant Erg Monitor run stop PLC Module No Present Error Year Month Day Time _ PLC Module Present Error Yeat Month Day Eea No enor Stop monitor Stop monitor Lu a Eror Jump Eror Jump e Help Help o zZ x Error log Error log Q Enorlog Clearlog Occurence order Ascending x Enorlog Clearlog Occurence order
89. az Zr D ZO ae rad Z o g ao o e o zZ O O ol w l D 2 O hA 8 3 Replacing Module in Redundant System 8 48 8 3 7 Procedure for Replacing Module mounted on the I O Station of Redundant System 8 TROUBLESHOOTING 8 49 MELSEC TA eries 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 I O module e Intelligent function module 5 Analog module temperature input module temperature regulating module and pulse input module 4 For changing modules online hot swapping using GX Developer refer to the following manual Eg QCPU User s Manual Hardware Design Maintenance and Inspection 2 For changing modules online hot swapping using GX Developer refer to the manual for the intelligent function module used POINT 1 When connecting the extension base unit use the Redundant CPU whose first 5 digits of serial No is 09012 or later in both systems In addition connect the redundant type extension base unit to the 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 swa
90. b Connecting the redundant type extension base unit to the redundant power g extension base unit E Connect extension cable from OUT connector on the redundant type extension base unit to IN connector on the redundant power extension base unit o zZ o O 35 if a O a 4 2 Wiring 4 11 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM MELSEC Kel ries 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 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 CPU module Power Switch 1 STOP RUN lt _ RESET L CLR Switch 1 RESET L CLR Diagram 4 9 CPU Module Switch Positions and Settings 1 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 4 4 Confirming that the Power Supply is ON 1 Powering on the system Check the power line and power supply voltage of the power supplies of the power supply modules of the main base units and extension base units in systems A and B and turn ON power supplies simultaneously 2 Confirming the Powe
91. e System switching using dedicated instruction e System switching by the intelligent function module 2 Special Registers For System Switching OSet Not set Special registers for system switching are shown in Table5 39 Table5 39 Special Registers For System Switching 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 common information category code for SD4 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 Control system switching instruction 17 Control system switching request from GX Developer Setting at Time of System Switching New Control System New Standby CPU Module System CPU Module SD16 Individual error information 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 Tracking cable malfunction cable disconnection cable malfunction internal circuit malfunction or hardware malfunction N Hardware failure power OFF resetting or watchdog timer error occurring on standby system Hardware failure power OFF resetting or watchdog timer error occurring w on co
92. eries 5 3 6 System Switching Precautions 1 System Switching Failure The control system may disappear and the redundant system may not function in any of the following cases a A tracking cable error including tracking cable disconnection has occurred during system switching due to hardware failure power off or CPU module reset b A communication error has occurred between the CPU modules during system switching due to a user instruction or a stop error c During system switching due to a user instruction or a stop error a tracking cable error including tracking cable disconnection has occurred concurrently with any of the following standby system conditions 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 Operations when the system switching fails due to one of a to c shown in the Table5 40 below Table5 40 System A and B CPU Module Operations When the System Switching Fails Function System A and System B CPU Module Operation CPU Module Operating Status Standby System Operation Red light ON in Backup Mode ede BACKUP LED Indication Amber light ON in Separate Mode CONTROL Light OFF SM1516 Special Relay Operation System Status ON Standby system System Switching Request from
93. 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 switching 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 System Switching High 4 e Control system powered off e Control system CPU module reset 2 e Stop error in control system CPU module y 3 e Execution of system switching instruction 4 e System switching operation using GX Developer cow 5 e System switching request by network module 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 41 5 3 The System Switching Function 5 3 1 System Switching Method D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries 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 i Sys
94. gt PID bumpless processing for incomplate 5y SM270 to SM272 MELSECNET H module 4 information SM794 Se derivative 96 SM1500 l m E SM321 Startup stop SFC program SM1501 Hold mode S IN S OUT instruction Zz SM1520 to a SM322 SFC program start status SM1583 Data tracking block specefication trigger Resence absence of Continuous transition for Standby system error detection disable flag at SM323 i SM1591 e o entire blocks system switching z SM325 Output mode at block stop SM1592 Enable disable user system switching Z 2 Copy contents of standard ROM during memory fo SM326 SFC device clear mode SM1598 Qe copy 20 SM327 Output during end step execution SM1649 Standby system cancel error flag Disable prohibition of system switching during SM402 After RUN ON for 1 scan only SM1709 online program change g SM403 After RUN OFF for 1 scan only SM1710 Transfer tracking data during online program 5 fe SM551 Reads module service interval change enable flag F WwW a 5 oO 5 5 Tracking Function 5 80 5 5 3 Tracking Data D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries 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 SD90 to SD99 Step transition watchdog timer setting value Enabled only when SFC program exists
95. gt lolli FG FG Qua AC 3 Ols LG LG ce m proof IIS INPUT INPUT on SIF AC100 HOM AC100 to 200V to 200V Redundant type extension base unit fa Q65WRB g tt N Q64RP Q64RP 1 O module z 2 O Extension cable Z 5 az 4 ty te R U Ol ERR Ol ERR f Olt FG ojm FG DINPUT INPUT m T oe E ProT actoo AC100 eevee lla Fok to 200V to 200V Grounding z 2 ao 100V 200VAC ZO p E a o5 AC EL Xooooooooo eZ 100V 200VAC o z Diagram 4 4 Example of Wiring to a Power Supply Module F 2 O 1 Operation of an ERR terminal is as follows SE lt When mounting power supply module to main base unit gt S 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 lt When mounting redundant power supply module to redundant type extension base unit gt a The ERR terminal is OFF open when AC power is not turned ON when fuse of the redundant 8 power supply module is blown or when the redundant power supply module breaks down a z O ao 4 2 Wiring 4 7 4 8 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM POINT 1 MELSEC TA eries Use the thickest possible max 2 mm AWG 14 wires for the 100 200VAC and 24VDC power cables Be sure to twist these wires starting at the connection terminals For wiring a terminal block be sure to use a solderless terminal To prevent short c
96. provided that the usage of the PRODUCT is limited only for the specific applications agreed to by Mitsubishi and provided further that no special quality assurance or fail safe redundant or other safety features which exceed the general specifications of the PRODUCTs are required For details please contact the Mitsubishi representative in your region REVISIONS The manual number is given on the bottom left of the back cover Print Date Manual Number Revision Jun 2004 SH NA 080486ENG A First edition Jun 2005 SH NA 080486ENG B partial correction GENERIC TERMS AND ABBREVIATIONS Chapter 1 Section 2 3 6 2 2 8 1 1 8 3 3 9 1 9 2 Aug 2005 SH NA 080486ENG C 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 Mar 2006 SH NA 080486ENG D 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 Jun 2006 SH NA 080486ENG E Model addition 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 Jun 2006 SH NA 080486ENG F Partial correction eee eee SAFETY PRECAUTIONS Appendix 4 3 Section 2 3 2 4 Appendix 4 5 Dec 2006 SH NA 080486ENG G Partial correction SAFETY PRECAUTIONS Section 4 2 5 5 3 7 1 7 3 8 2 Appendix 4
97. system 35 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 z Wi Network parameters Assignment the CC IE Control network range Module No 1 g Setup common parameters m ed EOT ne 53 es Aaa wets gy sence Statt End inal save Switch screens LB LW settings 1 z TB7LW setings 1 Set station No 3 Station No LB Pairing aa End_ Points Ponts or 4 pairing rf DOFF 256 Disable aa CFF 256 Disable 2 O2FF 256 Enable O O2FF 256 Enable oO osFF 256 Disable z g O Specify reserved station Equalassignment dentealPeht 26 pons ele a Siepemenan Clear Check End Cancel E R lt a a 204 aza Diagram 6 11 Network Parameter Settings i BS ZEA ange 1 In the debug mode the CPU module uses the parameters for system A to operate Therefore the station set as system B in the network parameters becomes absent station disconnected station if Refer to the following manual for network parameters A L gt CC Link IE Controller Network Reference Manual 22 es LSQ Corresponding MELSECNET H Network System Reference Manual 55 Lu PLC to PLC Network r ez W wn gt n j A Ed a Zz fa W a n X x e z E W zZ PROGRAMMING CAUTIONS TROUBLESHOOTING 6 2 Redundant System Network Overview 6 14 6 2
98. system which is the main base unit where the power ae 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 o e Diagram 8 12 Flowchart for when UNIT LAY DIFF Occurs o zZ O O ol w l D 2 O hA 8 1 Troubleshooting Flow 8 24 8 1 11 When UNIT LAY DIFF Occurs 8 TROUBLESHOOTING 8 1 12 When SP UNIT DOWN Occurs MELSEC TA eries The following shows the flowchart for when SP UNIT DOWN occurs during operation of the redundant system An error message SP UNIT DOWN was detected Is CC Link IE Controller Network module mounted YES Is first 5 digits of serial No of the Ne CPU module 10042 or later Is a module incompatible with the YES CPU module mounted NO Is the module on the relevant slot mounted correctly and the extension cable of the relevant base unit connected correctly NO YES Check operation starting from a minimum system For modules that do not operate consult your local Mitsubishi representative explaining a detailed description of the problem Replace the CPU module with the one whose first 5 digits is 10042 or later Remove the relevant module Mount the module on the relevant slot correctly or connect the extension cable of the relevant base unit correctly Diagram 8 1
99. 1 2 Tracking cable 1 Z EEEE lt fe Remote I O module MELSECNET H Remote I O network z Serial communication a A I module we UF I 2a rp woe 5 aot Remote I O station Remote I O station a 7 a lee aes fe E Mae 5 a l 28 H lagii ane 8 e i I Wh ifyi ae f p en specifying System switching l standby system using Wu J MC protocol 9 N z o Multiplexed Remote Sub master Station Multiplexed Remote Master Station Z 5 az Standby system Control system L wit B B al B g 6 ral B a ii i a a H E da E i Al LY E Tracking cable J i Z g i Hp d 1 95 z I W W Remote I O module ra MELSECNET H Remote I O network Si rc a Serial communication I module I z 5 o z L z Remote O station Remote O station eL e e je n T i lt Z iq I I When specifying standby system using MC protocol Z 8 Diagram 6 31 Operation for Communication with Standby System CPU Module by MC Protocol 5 5 ao 6 2 Redundant System Network Overview 6 40 6 2 5 Serial Communication Modules 6 REDUNDANT SYSTEM NETWORKS M ELSEG Eseries 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 syst
100. 1 CC Link IE Controller Network or MELSECNET H PLC to PLC network 6 REDUNDANT SYSTEM NETWORKS Power supply Power supply MELSEC TE eries Pairing settings can be made for the following CPU modules that can work as the control station e Redundant CPU High performance model QCPU 1 Process CPU 1 Basic model QCPU Universal model QCPU 1 e Q4ARCPU 12 When connecting a redundant system to the network that includes the CPU module other than above for which control station network parameters have been set change the system A or system B of the redundant system to the control station Change control station to normal station in network parameters Normal station Control station Power supply QnACPU AJ71QLP21 QnHCPU QJ71LP21 Power supply QnPHCPU QJ71LP21 Existing MELSECNET 10 PLC to PLC network Addition QnACPU AJ71QLP21 System A Control station System B Normal station a 2 Fi no is g fe a QnPRHCPU QJ71LP21 Power supply QnPRHCPU Tracking cable Diagram 6 12 Changing the Control Station When Adding Redundant System 1 Refer to Section 2 3 for GX Developer that supports a redundant system including pairing settings 2 The pairing settings cannot be made with the Q4ARCPU in the CC Link IE Controller Network 6 Startup Order of System A and System B No restrictions apply to the startup order of system A and system B when co
101. 3 4 MELSEC TE eries 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 L gt QCPU User s Manual Hardware Design Maintenance and Inspection 5 8 Online Module Change Hot Swapping 5 124 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series 5 9 Network Module Redundant Group Settings
102. 3 Replacing Module in Redundant System 8 50 8 3 9 Tracking Cable Replacement 8 TROUBLESHOOTING MELSEC TE cries 2 Replacement Procedure The procedure of replacing the tracking cable is shown in the Diagram 8 36 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 1 Disconnect the tracking cable from the control system CPU module Refer to Section 3 3 for disconnecting the tracking cable 2 Disconnect the tracking cable from the standby system CPU module 3 Connect the tracking cable connector to the standby system CPU module Refer to Section 3 3 for disconnecting the tracking cable 4 Connect the tracking cable connector to the control system CPU 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 Power on the control system 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 36 Tracking Cable Replacement POINT Make sure to replace the tracking cable after powering off the standby system or setting th
103. 4 1 Mounting Modules coooooooooooooooooooooooooo00000000000000000000000000000000000000000000000000000000000000000000000 A 6 4 2 Wiring cooococoooooooooooooooooooooo0000000000000000000000000000000000000000000000000000000000000000000000000000000000000 4 7 4 3 Module Initial Settingseccccccccccccccccccccsccccccscccccccccssccsvccsccsvccsccssccsoccsccccocssoscocssocsoossoees 4 12 4 4 Confirming that the Power Supply is ON COCCOOOOOO OOOO OOOOH OOOOH OOO OOOO OOOOH OOOO OOO OOOOH OOOO OOO OOOOO OOOO OCOOEE 4 s 12 4 5 Confirming System A System B cccccccccccccccccccccccccccccccccccccccccc ccc ccccccccecccccceccocecccocccoooocce 4 13 A 11 4 6 Starting up Connecting GX Developer eeeeeseeeeeeeeeesseesesesesecececcscocococececececosesssssssoseseeeeee 4 13 4 7 Writing Parameters and Programs to CPU seeeeeeeeeeeeeeeesesesesesececeseccscocococecececoeseesososssesoe 4 14 4 8 Restarting System A and System B sseeeeeeeeeeseeeeceescsscescsececesescsescocococecececcececsesssoseseseeee 4 15 4 9 Error Check sessesseesessessecsoseoscecooccoscoescecsoccosceoscecsecsoseoscecoecsoseessecoosooseessecsoseoseessessoe A 1G 4 10 Confirming the Control System Standby System seseeeeseesesesesesesesescseseecocececeesessesosesssesee 4 16 4 11 Running CPU ModulEs ecccccccoocoooooooooooo000000000000000000000000000000000000000000000000000000000000000000 4 16 CHAPTERS REDUNDANT SYSTEM FUNCTIONS 5 1 to 5 140 5 1 Basic Concept of Redundant System cococ
104. 48 z gt 5 Perfom tracking 2 transfer according to g defaults 20 bk HO Use GX Developer to change tracking setting redundancy parameters i T Section 5 5 3 a S o zZ x O Use GX Developer to add tracking forwarding triggers to the controlling program lt 3 gt Section 5 5 4 S W x e Sag 255 ags Write to the CPU module parameters set Write to the CPU module parameters set 5 5 Z with GX Developer and programs with GX Developer and programs RE D ol Perform a system restart Perform a system restart Turn ON tracking forward trigger using the program Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le W 12 gt wn ag ou zo Be W Ww ez Begin tracking transfer o zZ Completed g a Diagram 5 48 Tracking Execution Procedure 95 ao zZ fe E N W l a 5 a E 5 5 Tracking Function 5 76 5 5 2 Tracking Execution Procedure D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries 5 5 3 Tracking Data Tracking data are shown in Table5 43 Table5 43 Tracking Data Settings igs Setting Operating Mode 2 Description re Change by Backup Separate Tracking 9 User Mode Mode tema Die Data of input output Y internal relay M o O O O and others used in programs Device e paa turned ON or OFF by user or system 5 Data L gt Table5 46 Special Data
105. 5 Appendix 5 Apr 2007 SH NA 080486ENG H Revision involving Redundant CPU serial No 09012 Model addition Q65WRB Partial correction 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 8 3 9 Sep 2007 SH NA 080486ENG I Partial correction GENERIC TERMS AND ABBREVIATIONS Section 1 1 1 2 2 1 2 3 2 4 3 3 5 1 4 5 1 5 5 2 5 4 5 3 4 5 3 6 5 5 1 5 5 4 5 5 5 5 6 2 5 9 5 10 1 5 10 2 6 1 3 6 2 6 2 2 6 2 4 6 2 5 6 3 6 3 2 6 3 3 6 3 4 6 4 7 1 7 2 8 1 8 2 9 2 Appendix 1 Appendix 2 Appendix 3 Appendix 4 Appendix 5 Appendix 7 Nov 2007 SH NA 080486ENG J Revision due to a support of Redundant CPU having serial number 09102 and overall review Print Date Manual Number May 2008 SH NA 080486ENG K The manual number is given on the bottom left of the back cover Revision Revision due to a support of Redundant CPU having s
106. 5 a 5 ao 2 1 System Configuration 2 11 2 SYSTEM CONFIGURATION 2 2 Peripheral Device Configuration E Redundant CPU MELSEC TE cries Memory Card z RS 232 Cable E Personal Computer GX Developer PX Developer GX Simulator 3 l USB Cable J eeg gt L7 as Memory Card PC Card i Adapter Diagram 2 9 Peripheral Device Configuration 1 Do not format ATA cards for using other than GX Developer L gt 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 GX Developer Version 8 Operating Manual 3 Refer to Section 2 3 for versions of GX Developer PX Developer and GX Simulator applicable to redundant CPU 2 12 2 2 Peripheral Device Configuration 2 SYSTEM CONFIGURATION M IES 26 fel ceries 2 3 Applicable Devices and Software This section describes modules and software packages that can be used to configure a redundant system OVERVIEW N 1 Modules applicable to redundant system Modules shown in Table2 1 are mountable to a main base unit where a redundant CPU is mounted For any other module mount it to a MELSECNET H remote I O station or an extension base unit Note that however some modules cannot be mounted to MELSECNET H remote I O stations and extension base units 1 b c
107. A B LED lit up solid green NO Y Replace standby system s CPU module lt 5 Section 8 3 1 Clear the control system CPU module errors gt Section 8 2 Is the SYSTEM A B YES MELSEC TA eries LED lit up solid green NO kd Replace control system s CPU module lt gt Section 8 3 1 y Clear the control system CPU module errors gt Section 8 2 Is the SYSTEM A B YES LED lit up solid green Please contact the nearest Mitsubishi represenative reseller or branch office and explain the fault symptoms Completed Diagram 8 5 Flow for the Case where the SYSTEM A B LED is Flashing 8 9 8 1 Troubleshooting Flow 8 1 3 When the SYSTEM A B LED is flashing TROUBLESHOOTING MELSEC KE 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 ai module RUN LED is not on i 5 The RUN LED does not light up 9 E NO Separate mode 3 Is the running mode i 2 set to backup 2S mode 1 ae YES Backup mode WwW a lt S Is the control system 9 a Normal the standby system CPU z CPU module RUN LED module RUN LED is not ON not lighting up 2 a E E x a lt 2 eee Reset with the CPU module s voz Is the RUN LED ON RESET L C
108. Allow removing the memory card Station no Host PLC type Q25PRH feel leet N coo Operation mode Separate mode Tracking cable Specify execution destination Currently specified station Allstations Specific group GX Developer 5 135 Diagram 5 103 Remote Reset Operation in Separate Mode 5 10 Redundant CPU Functions Restricted in Redundant System 5 10 2 Remote Operation for Redundant System D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries 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 S x Lu 3 1 Remote reset when control system CPU module is i
109. B LED of each CPU module 2 PROGRAMMING CAUTIONS TROUBLESHOOTING 4 4 2 PROCEDURE FOR STARTING UP A REDUNDANT SYSTE M M ELSEG Q series Connecting to the PC in which GX Developer is Installed Refer to Section 4 6 1 Start up GX Developer in the GX Developer installed PC 2 Connect the PC in which GX Developer is installed to the system A CPU module l Writing Parameters and Programs to CPU Refer to Section 4 7 Write the parameters and programs created with GX Developer to the CPU modules of System A and System B l Restarting System A and System B Refer to Section 4 8 1 2 Power off system A and system B or toggle RESET L CLR switch of CPU module Simultaneously power on system A and system B or simultaneously set the RESET L CLR switches of both CPU modules to reset switch neutral position Error Check Refer to Section 4 9 Check if the ERR LEDs of system A and system B CPU modules are OFF If the ERR LEDs are ON flashing check the error cause using the System Monitor or diagnostics of GX Developer and eliminate it Checking the Control System Standby System Refer to Section 4 10 Check the control system standby system by the CONTROL LED status of each CPU module 1 2 Running Standby System System B CPU Module ee Refer to Section 4 11 Set the RUN STOP switch of standby system CPU module
110. 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 Appendix 6 Precautions for Using Serial Communication Module App 32 APPENDICES MELSEC Aries Appendix 6 1 CSET Instruction 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 W O signal Table App 14 List of I O Signal VO signal ee A Signal name Description of signal CH1 side CH2 side X n 1 E Q series C24 ready ON Accessible ON Module error occurred Watchdog timer error X n 1 F OFF Module being normally WDT error operated 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 CH1 side CH2 side 961 150 136 4 310 Word byte units designation Buffer memory name POINT Set the send receive data length unit setting b
111. 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 Standby system oooooo nooo ooo000 ooo eem le ejs sleale Col Coz Fong oojoo I aa aa Bl P Cie o Tracking cable ally Replace after using GX Developer to switch over to the standby system GX Developer Diagram 8 32 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 Tracking cable Replace after turning OFF the GX Developer standby system power Diagram 8 33 System where Standby System s Main Base Unit Is Replaced 8 3 Replacing Module in Redundant Syste
112. Begin system switching System Switching complete I I w I i SCJ Instruction ON 1 T EA Point l l OFF l 9 l I Z I I Z l l After switching Jump od doniol Jump i i from the first scan system Do not jump l l I I I l SCJ jum l aw onl Jump i fi system Do not jump l l 5 z A System switching l mE 5 T Dot aza WEZ Or When Signal flow memory is tracking RE D Begin system switching System Switching complete l i scan I W ON h l D SCJ Instruction l l l D Point l l 1 E OFF r I A 2 I l al a j 1 l After switching Jump 30 oa ond Jump i from the second scan D 5 system Do not jump i 1 ji i i SCJ jum i l aw conlrol Jump a system Do not jump l l I x I wn le System switching k Eg aX Diagram 7 3 ON OFF Operation of SCJ Instruction When Signal Flow Has Been Tracked Z 5 BG ez bas z o a g OF o3 E ao TROUBLESHOOTING 7 1 Instructions Restricted in Use for Redundant System T 5 PROGRAMMING CAUTIONS MELSEC TE cries 5 Instructions that Change CPU Status 6 0 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 Statu
113. C fa ti H E Pl al BRE lel gia 2 1 Specify standby Ai CC Link system on GX Developer REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Diagram 6 3 Communication with CPU Module via Tracking Cable b Accessing a Network Module via a Tracking Cable Communication with a network module on the other system via a tracking cable is not available for GX Developer and PX Developer To communicate with a network module on the other system e g network diagnosis of the other system reconnect the GX Developer and PX Developer to the CPU module on the other system REDUNDANT SYSTEM FUNCTIONS ez CC Link Master Module W wn gt n j rA Ed a Zz fa W a Yn x Control system Standby system 9 y Fs E D S 8 fl el a a g g Za a l a Sl i f a O a g a S Ea BI 4 3 z Z sf 3 O Specify CC Link master module in standby system CC Link Y NX x I l PROGRAMMING CAUTIONS GX Developer z
114. CPU module ERR LED flashing system CPU module and check for faulty behavior using the System Monitor PLC diagnostics 2 Y module errors gt Section 8 2 Connect GX Developer to the standby YES standby system s CPU module Correct abnormal behavior of the Clearing control system CPU Is the BACKUP LED lit up solid green module errors Section 8 2 YES YES 1 Completed 8 1 Troubleshooting Flow 8 1 2 When the CPU Module BACKUP LED is ON Red TROUBLESHOOTING MELSEC TE eries 1 Power off the standby system OVERVIEW Disconnect and then reconnect the tracking cable lt 37 Section 3 3 Power on the standby system SYSTEM CONFIGURATION Reset the error of the control system CPU module Refer to Section 8 2 TRACKING CABLE Is the BACKUP LED lit green Replace the tracking cable lt gt Section 8 3 9 REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Clear the control system CPU module errors 3 Section 8 2 Is the BACKUP LED lit up solid green REDUNDANT SYSTEM FUNCTIONS Replace standby system s CPU module lt 3 gt Section 8 3 1 Clear the control system CPU module errors gt Section 8 2 REDUNDANT SYSTEM NETWORKS Is the BACKUP LED lit up solid green PROGRAMMING CAUTIONS 2 3
115. CPU from Other Networks 6 52 6 REDUNDANT SYSTEM NETWORKS GX Developer Control system specified Example M ELS EC Eerie Diagram 6 40 shows a system configuration example for making communication 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 Nec x Nicaea 4 MC protocol i i Control system specified Ethernet network No 4 MELSECNET H PLC to PLC network network No 1 lt CWELSECNET Medill network No 1 gt QCPU can communicate with Redundant CPU regardless of serial No Relay d lt CMELSECNET H PLC to PLC network network No 2 gt MELSECNET H PLC to PLC network network No gt stations CPU2 Relay station E _ MELSECNET H PLC to PLC network network No 3 e Control system Standby system F JE Z J CPU module Serial No of CPU module El fl E B E on relay station 06051 or earlier 06052 or later a ka a e dl
116. Control system a sa D00000 JJ The new control system s Stop Error has ieaie i d g w normal station becomes the occurred s P sub control station and F maintains the data link 0 Tracking cable J So S5 Diagram 6 8 Operation When System Switching Occurs Due to Control System Error tars o 5 0 E v W l a fe hd 6 2 Redundant System Network Overview 6 10 6 2 1 CC Link IE Controller Network or MELSECNET H PLC to PLC network 6 REDUNDANT SYSTEM NETWORKS MELSEC TE eries 3 Redundant System Operation when a Communication Error Occurs in CC Link IE Controller Network or MELSECNET H PLC to PLC Network a Continuation of Data Link via System Switching When a communication error occurs in CC Link IE Controller Network or 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 switc
117. Developer that changed the mode from backup mode to separate mode If the control system CPU module however is powered off or is reset in separate mode the operation mode can be changed back to backup mode using any GX Developer When different GX Developer is used to change the operation mode back to backup mode the error dialog box Diagram 5 35 appears If the error dialog box appears change GX Developer to the one used to OVERVIEW change the mode to separate mode or reset the control system CPU module E MELSOFT application CONFIGURATION SYSTEM q Other routes are changing operation mode 1 Please execute it again by the route which executes the operation mode change lt E5 010a4259 gt Diagram 5 35 Error Dialog Box Displayed on GX Developer 3 The operation mode cannot be changed from separate mode to backup mode using GX Developer when the control system CPU module operation is stopped the RUN LED of the CPU module is flashing 4 Operation mode cannot be changed in the following situations e When standby system is powered off or the standby system CPU module is being reset If the error dialog box Diagram 5 36 appears on GX Developer turn the standby system on again or clear reset on the CPU module and then change the operation mode TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol E MELSOFT application Unable to communicate with PLC The following reasons may be respon
118. Device Eile ms AEN Instruction Data Register RUN O Q O O O RUN STOP PAUSE O O O O O Stop Error x x x x x RUN O O O O O STOP STOP PAUSE PAUSE O O O O O Stop Error x x x x x O Tracked x Not tracked 1 Device data Indicates the internal devices set at the tracking settings in the redundant parameter settings Section 5 5 3 Indicates the special relays and special registers that will be automatically tracked Section 5 5 3 5 5 Tracking Function 5 88 5 5 6 Tracking Execution OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu E n gt N i Z lt Q Zz a W X o Z O O Z Le REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q 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 Speclal Relay SFC Data sus Gontro Internal Device and Special Instruction Data Register RUN O x x x x RUN oe O x x x x PAUSE Stop Error x x RUN O STOP STOP PAUSE PAUSE O i x 3 x Stop Error x x x x x RUN x x x x x Stop Error SOR x x x x x PAUSE Stop Error x x x x x Performs tracking x Does not perform trackin
119. H Remote I O Network 5 _ Zv om zO ae WW Ww Yz 9 zZ o 56 z AS 0 zZ fe 35 N Lu l a hd 1 2 Features 1 9 1 OVERVIEW 1 10 MELSEC TA eries 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 terminator Bus terminator o0 00 o0 oo onononon onon0n0 onononor onononon on0n0000 ou on on 0G 0000000 ononon 00000000 onon 0000 enon onog onononop ogononon DP Slave DP Slave Control Standby system An error has system been detected New standby New control system system EIQ al E Tracking cable F Bus terminator g Bus terminator z m 8 eee esses fF OO OOJOO OO OOJOO 00 i 88 3988 28 83 85 88 33 33 38 38 83 85 33
120. Instruction APPENDICES MELSECTE cries The program example for mode switching is shown in Diagram App 27 For the I O signal is X Y80 to X Y9F PROCESSING TIME FOR REDUNDANT SYSTEMS 0 f f sae ae f MOV K1 DO Changes operation mode into MC protocol format 1 MOV H85B0 D1 Sets transmission specification 7 TO H8 H90 DO K2 Writes mode switching specification contents to ra buffer memory a W a a Prd SET Y82 Sets mode switching request X86 17 y RST Y82 Resets mode switching request signal FROM H8 H203 D2 K1 Reads error description after switching mode rc 4 x l D2 KO SET M50 j Completes mode switching m M50 ee 29 Setti tue ch buff if Changes setting value of communication protocol Mt i aa a a a G aa according to communication specifications RST M50 Resets mode switching completion X8E pn e eee eee eee e eens 32 i Error processing LED OFF error code clear H X52 34 s ASA Y82 7 Clears mode switching request by clear request Diagram App 27 Program Example 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 Appendix 6 Precautions for Usin
121. K1 K10 H1 H100 D200 K10 M203 H of Station No 10 ng 26 SM1518 M203 E HO 35 ft RST M200 Turns OFF M200 to M202 on RST M201 completion of the REMFR instruction execution u a RST M202 S Z M204 eee i i Processing at normal completion H T EE NEEN E E E E E E ee J M204 ee OREORE SEREA E EEE EOE EEEE SOES i m Processing at abnormal completion H ED fesse E E ee ee ee ee A R an me a a Ge ee ee J W 5 2 Diagram 7 2 Example of REMFR instruction programming if z 298 2 The instruction that includes no execution completion signal or write instruction Se 5 needs to be executed again as it is difficult to determine if its execution is Eor completed or not However note that the same instruction might be executed twice E i gt wn S zn 6 ZE DOG A A tE W E 12 gt wn S Zg aia zO Be W Ww ez bas z o a g OF o3 E ao TROUBLESHOOTING 7 1 Instructions Restricted in Use for Redundant System T 3 PROGRAMMING CAUTIONS MELSEC TE eries 2 Rise Instruction 3 If signal flow memory has not been tracked after system switching the rise instruction is processed as explained below a Processing When the systems are switched the new control system CPU module turns on data in the signal flow memory For this reason the CPU module does not execute the rise instruction even though the rise instruction execut
122. Link IE Controller israel Network CPU to link Continues execution R i ple No change from before operation mode change Link to CPU Continues execution Continues execution MELSECNETI H PLC to Bicker PLC network CPU to link Continues execution A ee he ite No change from before operation mode change 1 0 Link to CPU Continues execution Continues execution MELSECNET H remote a eae 1 O network CPU to link Continues execution DES NOLEXC EME Lene 5 63 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 CC Link IE Controller Network MELSECNET H CC Link Link to CPU Continues execution Continues execution CPU to link Continues execution 5 4 Operation Mode Change Function Does not execute refresh No change from before operation mode change D REDUNDANT SYSTEM FUNCTIONS From Separate Mode to Backup Mode D Control system Standby system Continues execution Stops Stops continues Stops continues Takes over t
123. O 7 a e B CH i Tracking cable oe Lu CC Link a V V GX Developer ai S Remote Intelligent x REE Device Device lt Station Station E AnACPU AnUCPU AnNCPU Personal Normal Normal Normal P computer station station station a oma oa g A z z D C MELSECNET H MELSECNET 10 Mode PLC to PLC network D 4 Be Extension base unit mee Or QCPU QnACPU Q4ARCPU oan Normal Normal Normal station ange MELSECNET H Remote I O network station station Control station Remote I O station gt angle Remote Remote p 2o N IA v az alg I O station I O station a SOINS E g EISIR Zn 6 a Ze DO a5 External device rane ez Diagram 6 6 Redundant System Network W wn gt n j A Ed a Zz fa W a n X x e z E W zZ PROGRAMMING CAUTIONS TROUBLESHOOTING 6 2 Redundant System Network Overview 6 8 6 REDUNDANT SYSTEM NETWORKS M ELSEG Q series 6 2 1 CC Link IE Controller Network or 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 communication as the control system and standby system form one system The standby system network module receives cyclic data f
124. ON Circuit is added to System B CPU module Refresh to the network module MO Mo 100 4100 Co gt I Refresh to the network module Mo Mo E Y100 4100 C Y100 external output OFF ON Vy Diagram 5 67 Operation When System Switching Occurs during Online Program Change 5 6 Online Program Change for Redundancy 5 6 2 Program Change While CPU is Running D REDUNDANT SYSTEM FUNCTIONS M aL 26 Kel eries 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 gt x System A CPU module System B CPU module z Control system Standby system Device P ooram p Device data 9 rogram data Data before Data before changing changing 5 O Perform write m m x during RUN ae Data after change Ww z S 2 Perform write gZ during RUN lt Data after change VT i x 2 lt 5 If a system switching occurs in this zone the System B g 72 z CPU module will perform control based on device data A p calculated by the program after modification 3 Y a Eor Diagram 5 68 Program and Device Data due to System Switching Timing ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM PROGRAM
125. Operation for Communication with Control System CPU Module by MC Protocol M 5 5 a 6 2 Redundant System Network Overview 6 38 6 2 5 Serial Communication Modules 6 REDUNDANT SYSTEM NETWORKS Mi ELSEG Q series 2 When mounting to the main base unit 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 Standby system Le Control system ieam colm Remote I O module Serial communication a module Remote I O station Remote I O station T L When specifying control system using System switching E F activated MC protocol INE Multiplexed Remote Sub master Station Standby system L Control system
126. Reference Manual PLC to PLC network QnA Q4AR Corresponding MELSECNET 10 Network System Reference Manual TRACKING CABLE PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 2 1 System Configuration 2 5 2 SYSTEM CONFIGURATION MELSEC IA series Normal station Normal station Normal station Normal station QnHCPU QnACPU Input module Input module Input module QJ71E71 QnPHCPU QJ71LP21 Input module Input module AJ71QLP21 Input module Input module Q4ARCPU Input module Input module Input module AJ71QLP21 Output module Output module Output module Power supply module Power supply module iPower supply module MELSECNET H MELSECNET 10 Mode PLC to PLC network communication with other stations Normal station Normal station System A System B Control System Standby System Control station Normal station System B Standby System System A Control System QJ71LP21 QJ61BT11N QU71E71 QnPRHCPU QU71LP21 QJ61BT11N QJ71E71 RIS g a a ajz amp 5 N N 2 9 2 QnPRHCPU QJ71GP21 SX QU71GP21 SX Pairing setting is required Pairing setting is required Diagram 2 5 Connection of Redundant System to MELSECNETI H PLC to PLC Network 1 Before making the pa
127. 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 After starting up system A and system B the control system and standby system are determined and then the data link is started Checking the Standby System Operating Status After power ON the status of a MELSECNET H module on the standby system can be checked with the following link special relays SB on the control system CPU module side SB0075 Remote master station cyclic transmission status e SB0076 Remote sub master station cyclic transmission status When both of the above link special relays SB are OFF the MELSECNET H module on the standby system is running normally 6 2 Redundant System Network Overview 6 22 6 2 2 MELSECNET H Remote I O network OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM REDUNDANT SYSTEM FUNCTIONS ez W wn gt n j A Ed a Zz fa W a n X x e z E W zZ PROGRAMMING CAUTIONS TROUBLESHOOTING 6 REDUNDANT SYSTEM NETWORKS M ELSEG Q series 8 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
128. Switching Timing Tracking Data Not Received Device in which Initial Value is A CPU Module Device Data CPU Module Device Data Received Tracking Data Device in which Initial Device E Valie is set 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 Prepare tracking data Prepare tracking data Prepare tracking data Initial execution type program Waiting END Waiting EN Waiting Initial processing J Scan execution 0 J Scan execution 0 A Scan execution l type program type program type program Control _ ______ ___f _ _ _ a a s See s ee system CPU 5 module Send Send m Send 1 Tracking processing Tracking processing H racking processing Receive po Receive L Receive L Initial processing a tracking data N tracking data system CPU module Tracking data Tracking data not received received 4 Receiving Tracking Data Diagram 5 58 Tracking Operation Timing in Program Synchronized Mode 5 95 5 5 Tracking Function 5 5 8 Device Data Used By The New Control System D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries 5 6 Online Program Change for Redundancy In the backup mode GX Developer writes the same program to the control system and
129. 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 1 2 3 4 System A Control System System B Standby System oO o o z gIGANnE eolzm e ooo esau i here my 1 Hoag EDN 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 Sec
130. System Consistency Check In order to continue the redundant system control after system switching the system ai configurations parameters and programs of the control system and standby system must i be consistent 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 x operates as shown below according to the check results 1 r e If the control system and standby system are consistent in the system configuration parameters and programs the redundant system operates normally 2 nO 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 1 This check is referred to as Consistency Check Between Systems A and B Af The consistency check is executed in the following cases 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 simultaneously e During END processing by the control system CPU module e When the tracking cable is reconnected y Sa Table5 9 shows consistency check points and Table5 10 shows execution conditions m SE 20141 4 Check the memory 1 Check file contents T z card installation status 2 E an Program File Program File T MITSUBISHI Program
131. TE eries 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 System A Control System a 3 g z g fault a System switching when a fault occurs in the control system Control system Error System A Control System gt Standby System B 5 J 5 35 fault 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 A stop error occurs in the control system CPU module 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
132. TROUBLESHOOTING 5 6 Online Program Change for Redundancy 5 106 5 6 2 Program Change While CPU is Running D REDUNDANT SYSTEM FUNCTIONS 5 107 MELSEC TA eries 7 Precautions a When program memory space is insufficient for writing files in RUN To write files to the program memory in RUN a working memory area free area as large as the size of the files is required If a sufficient working memory area is not reserved in the program memory writing files in RUN is not executable However if the necessary space is available in a memory card SRAM card or ATA card a batch of files can be written into the card during RUN b Memory used for writing files in RUN When writing files in RUN the same kind of memory is used for the control and standby system CPU modules If different memories are reserved for them writing files in RUN is not executed Table5 57 Memories for Control System and Standby System CPU Modules and Executability of Writing Files in RUN Memory available for control Memory available for standby system O x Memory card x O system Program memory When writing files in RUN fails the error dialog box in Diagram 5 70 appears W MELSOFT application i Exceeds specified memory range Check and retry lt E5 0180204a gt Diagram 5 70 Error Dialog Box Displayed on GX Developer c Operations disabled during online program change Do not perform the following operation d
133. Tracking Trigger SM1529 Tracking Block No 10 Tracking Trigger OFF Disable SM1530 Tracking Block No 11 Tracking Trigger Tracking OFF User 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 SM1535 Tracking Block No 16 Tracking Trigger SM1536 Tracking Block No 17 Tracking Trigger SM1537 Tracking Block No 18 Tracking Trigger SM1538 Tracking Block No 19 Tracking Trigger SM1539 Tracking Block No 20 Tracking Trigger SM1540 Tracking Block No 21 Tracking Trigger 5 5 Tracking Function 5 5 5 Tracking Block And Tracking Trigger 5 86 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu wn gt wn Zz a a Zz fa W a o Z O O Z Le REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 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 Trigg
134. Transmissi n buffer memory length designation A6p 166 146p 326 Recent burner memory head address designation A7p 167 147 4 327 epee burner memory length designation EJPOINT 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 On demand function of MC protocol e Send receive function of nonprocedural protocol e Send receive function of bidirectional protocol Appendix 6 Precautions for Using Serial Communication Module App 34 Appendix 6 1 CSET Instruction APPENDICES MELSEC TA eries The program example of specifying the send area head address and the send area size is shown in Diagram App 24 For the I O signal is X Y80 to X Y9F MOVP HOCOO MOVP H100 TOP H8 HOA2 DO Diagram App 24 Program Example DO D1 K2 J Sets DO to head address CO0w Sets D1 to buffer memory length 1004 Writes send area setting value The program example of specifying the receive area head address and the receive area size is shown in Diagram App 25 For the I O signal is X Y80 to X Y9F a MOVP HODOO MOVP H300 TOP H8 HOA6 DO Diagram App 25 Program Example App 35 Appendix 6 Precautions for Using Serial Communication Module Appendix 6 1 CSET Instruction DO D1 K2 Sets DO to head address
135. Troubleshooting Flow 8 1 6 When System Switching has failed Wait for online program change to complete TROUBLESHOOTING MELSEC TE eries 3 a hA W gt 6 Check operation starting from a minimum system and work your way g up For modules that are not A functioning contact the nearest m z Mitsubishi represenative reseller or as For the control system branch office and explain the fault network module are there symptoms any faulty modules SD1690 0 c a lt S 0 x 6 4 Confirm the status of the standby system network module modules compatible with SD1690 bit set to ON and correct any problems X y P lt woe Using GX Developer or a switching a S 5 instruction reissue a system switching om request and check that the system 2 F switches Zoe W D gt wn 5a Did the switch occur normally 456 2E DOG as ew Check again following the flow for Completed 2 systems did not switch If the 2 systems do not switch for the same E reason even after performing the Z 2 above checks please contact the a 5 nearest Mitsubishi represenative a reseller or branch office and explain ee the fault symptoms Diagram 8 9 Flow in the Case of System Switching due to Control System Error or System Switching Instruction Execution 9 zZ o 56 e ar ao o e o zZ O O ol w l D 2 O hA
136. Use REMFR REMTO for accessing Or in GX Configurator configure the settings for intelligent 1 function modules on remote I O stations The following modules cannot be mounted to remote I O stations CC Link IE Controller Network module MELSECNET H network module interrupt module Web server module MES interface module PROFIBUS DP master module PROFIBUS DP slave module PROFIBUS DP interface module DeviceNet master module DeviceNet slave module and AS i master module PROCESSING TIME FOR REDUNDANT SYSTEMS APPENDICES INDEX System System Expansion via Applicable Extension base units maximum For Ethernet interface modules dedicated 7 levels instructions interrupt pointers e mail function communication by the fixed buffer FTP server function web server function is not usable For intelligent function modules other than the above dedicated instructions and interrupt pointers are not usable lt lt First 5 digits of serial No is 09012 or later gt gt Applicable Extension base units Up to 7 The following modules cannot be mounted Interrupt module CC Link IE Controller Network module MELSECNET H network module Ethernet interface module function version B or earlier Web Configuration Extension Base Unit server module first 5 digits of serial No 09011 or earlier PROFIBUS DP master module PROFIBUS DP slave module PROFIBUS DP interface module DeviceNet master modul
137. Used By The New Control System COOCOOO OOO OOOO OOOOH OOOO OOOO OOOO OOOO OOOOH OOO OOOOH OOOS 5 95 5 6 Online Program Change for Redundancy ccoooooooooooooooo00000000000000000000000000000000000000000000000000 D OG 5 6 1 Writing to the CPU Module in STOP Statusecccccccccccccccccccccccccccccccccccccccccccccccccccccoccccs 5 96 5 6 2 Program Change While CPU is Running ccoooooooooooooooo00000000000000000000000000000000000000000000H _ 100 5 7 Memory Copy From Control System To Standby System 0cooocoooooooooooooo0000000000000000000000000000 F 111 5 8 Online Module Change Hot SWAPPING eeeeeececcccccccccccccccccccvcccccccccscccsocccccsecccocscocsoossoosel 123 5 9 Network Module Redundant Group Settings ccoooooooooooooooooooooooooo00000000000000000000000000000000000 125 5 10 Redundant CPU Functions Restricted in Redundant System eeeeeesseeeeesseeeeesceeoecosoooeeooo00005 127 5 10 1 Enforced ON OFF of external 1 0 ccoooooocooooooooooooooooo000000000000000000000000000000000000000000000F 127 5 10 2 Remote Operation for Redundant System ccoooooocooooooooooooooo0o0000000000000000000000000000000000 F 131 5 11 Access to Module Mounted on Extension Base Uniteccececcccccccccccccccccccccccccccccccccccccccoscsccee _ 139 CHAPTER6 REDUNDANT SYSTEM NETWORKS 6 1to6 55 6 1 Communication with GX Developer and PX Developer coooooooooooooooooo0000000000000000000000000000000000 V _ 1 6 1 1 6 1 2 6 1 3 Communication Methods with GX DevelOopEr
138. Watchdog Timer Error Startup as control system wir System System System System 26 Control Standby Control Standby os Hardware Failure Startup as control system Automatic System System System System System Control Standby Control Standby PESA Power OFF Startup as control system Switching System System System System i Control Standby Control Standby a Reseting Startup as control system O System System System System g System Switching BE 5 Control Standby Control Standby System switching will causes system B lt Request by Network ee 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 a System System Switching b 5 2 a ae 7 a 9 Y control Standby Control Standby P lt Switching System Switching Startup as standby system uge System System System System SoZ Instruction aza OFS oga crew anger Table5 29 Operations When System Switching Cannot Be Executed Due to Error Other Than Stop Error in the Standby System 5 Syst Status Before System System status Anten Z stem u 3 4 3 Control System aes 4 System Switching Operation After System B Power Switching ove es Switching cx a Method Switching Condition Condition eo 3 ee Co System A System B System A System B 5 6 Stop Error Other Than Control Standby Standby Control ag Startup as control
139. When the tracking cable is not connected or broken W wn gt n j A Ed a Zz fa W a n X x e z E W zZ PROGRAMMING CAUTIONS TROUBLESHOOTING 6 1 Communication with GX Developer and PX Developer 6 6 6 1 3 Cautions on Access from GX Developer and PX Developer 6 REDUNDANT SYSTEM NETWORKS MELSEC TE cries 6 2 Redundant System Network Overview A redundant system can be applied to the following seven networks Network modules must be mounted on the main base units e CC Link IE Controller Network MELSECNET H PLC to PLC network e MELSECNET H Remote I O network e MELSECNET 10 PLC to PLC network Ethernet CC Link PROFIBUS DP 41 When connecting to MELSECNET 10 PLC to PLC network in redundant system set MELSECNET H to MELSECNET 10 mode For details refer to the following manual L gt Q Corresponding MELSECNET H Network System Reference Manual PLC to PLC network The above networks can continue the data link and communication with external devices even when an error occurs in the control system However system switching does not occur when an error occurs in the CC Link The system switching dedicated instruction is necessary to perform system switching Refer to the corresponding network manual for details of the network used The network modules for networks other than the abovementioned and serial communication modules etc cannot be mounted on a main base
140. Z Le System A Control System Standby System Control RUN system Execute program il COU A1SSIam oo0000 oon ee oi oong i eI gt eee mig avail faa meoies f Tracking cable Diagram 5 24 System switching operations requested by the network module REDUNDANT SYSTEM NETWORKS 1 For the Ethernet interface modules only the QJ71E71 100 can detect wire break PROGRAMMING CAUTIONS TROUBLESHOOTING 5 3 The System Switching Function 5 36 5 3 1 System Switching Method D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series EJIPOINT 1 The network module system switching can only be requested from a redundant system compatible CC Link IE Controller Network module MELSECNET H module Ethernet module and PROFIBUS DP master module Refer to Section 2 3 for details on serial Nos of these redundant system compatible modules 2 When the Ethernet module is mounted on the extension base unit the system switching request cannot be issued The CC Link IE Controller Network module and MELSECNET H module cannot be mounted on the extension base unit If the network module cable is disconnected the system s
141. a Diagram 6 4 Access to Network Module via Tracking Cable TROUBLESHOOTING 6 1 Communication with GX Developer and PX Developer 6 4 6 1 3 Cautions on Access from GX Developer and PX Developer 6 REDUNDANT SYSTEM NETWORKS MELSEC TE eries 2 Corrective Action when a Line Down Occurs during Access via a Network a b 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 MC protocol commands that can be used for communications made via a module on an 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 C gt GX Developer Version 8 Operating Manual L gt PX Developer Version 1 Operating Manual Programming Tool 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 c
142. according to the error code stored in D20 Turns OFF the send request signal Turns OFF the LED and clears the error code Appendix 6 Precautions for Using Serial Communication Module App 54 APPENDICES MELSEC KE eries 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 PROCESSING TIME FOR REDUNDANT SYSTEMS 1 Device of programmable controller 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 APPENDICES 2 W O signal Table App 46 List of I O Signal I O signal Signal name Description CH2 side XnA Reception data read request ON Requesting read ON Module error occurred OFF Module being normally operated ON Data read completed Watchdog timer error WDT error Reception data read completion X n 1 F INDEX 3 Buffer memory Table App 47 List of Buffer Memory Buffer memory address Hexadecimal decimal Stored value CH1 side CH2 side 0 Normal completion 25814 600 268 616 Data reception result 1 or more Abnormal completion error code Receive data count 0 No receive data 600 1536 A00 4 2560 Number of data for which 1 or more Number of receive data read is re
143. and the System B CPU module as a standby system 8 19 8 1 Troubleshooting Flow 8 1 7 When TRK INIT ERROR error code 6140 Occurred at Redundant System Startup 8 TROUBLESHOOTING M eLS 26 Kel ceries 8 1 8 When CONTROL SYS DOWN error code 6310 to 6312 Occurred at Redundant System Startup OVERVIEW 1 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 system was powered off e The CPU module in either system was reset and then its RESET switch was set to the neutral position CONFIGURATION SYSTEM 2 Corrective action for CONTROL SYS DOWN If CONTROL SYS DOWN has occurred during a startup of the redundant system restart the system by performing either of the following operations a Power on System A and System B again 1 Power on System A and System B again simultaneously 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 Reset the System A and System B CPU modules and then set their RESET switches to the neutral position simultaneously PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM 2 The System A CPU module starts as a control system and the System B CPU m
144. between System A amp B 5 65 5 4 Operation Mode Change Function D REDUNDANT SYSTEM FUNCTIONS M aL 26 fel ceries OVERVIEW From Separate Mode to Backup Mode 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 File Operation status e Main base mounting status e Parameter valid drive TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 4 Operation Mode Change Function 5 66 D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series a Operations When Changing from Backup Mode to Separate Mode Back up mode Separate mode Control Stopping Calculation Start calculation system Standby Control system Standby Switch to separate mode Input data Multiplexed Input data muttipiexed e Multiplexed input data ees Ii QnPRHCPU Remote Master QnPRHCPU Remote i Remote Master QnPRHCPU Sub master i Output Data Station Sub master i Station Output Data
145. calculating An error occurred in the Control System 4 gt Control System gt Standby System ystem System cong Tracking cable Diagram 5 8 System Switching Operation in Backup Mode 5 1 Basic Concept of Redundant System 5 1 3 Operation Mode D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries a Confirming Backup Mode Confirm that the redundant system is running in the backup mode by checking the BACKUP LEDs of CPU modules OVERVIEW Table5 5 Checking the BACKUP LED to Confirm the Backup Mode CPU Module LED LED status Q12PRHCPU Control Standby MODE LED Name RUN System System Ea BACKUP ON green ON green BOOT CONFIGURATION SYSTEM Refer to the following manual for details on the CPU module LED L gt QCPU User s Manual Hardware Design Maintenance and Inspection b Precautions TRACKING CABLE 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 operat
146. 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 Table App 12 Refresh Devices Address Transferred Auca E Remote Input RX RX0 RX9F 224 E0H X1000 X109F Remote Output RY RY0 RY9F 352 160n 10 Y1000 Y109F Remote Register RWr RWr0 RWr20 736 2E0n 20 W1000 W1013 Remote Register RWw RWw0 RWw20 480 1E0n 20 W1100 W1113 Special Relay SB SBO SB1FF SB400 SB5FF Special Register SW SWO0 SW1FF SW400 SW5FF 41 Indicates the number of transferred data that is specified in the BMOV instruction Appendix 4 Sample Programs when Using CC Link Appendix 4 3 Devices Used in Programs APPENDICES MELSEC KE eries Appendix 4 4 Parameter Settings The PLC parameters and network parameters for using the sample program are shown here PROCESSING TIME FOR REDUNDANT SYSTEMS 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 Q parameter setting APPENDICES Program MAIN KIRIKAE INDEX x x x X X X X x x x x X X File usability setting 1 0 refresh se
147. eries 5 4 Operation Mode Change Function 2 types of redundant system operation mode change are available gt e 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 1 Operation Mode Change Procedure The operation mode change is performed in the control system CPU module by the 0 redundant operation of GX Developer Ei O nO 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 m open the Redundant operation screen 3 o 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 2 5 Set the RUN STOP switch of the standby system CPU module to 5 2 RUN STOP RUN or use GX Developer to change from remote STOP to Boe remote RUN With this setting the CPU module starts running and executes BE 4 reg Run in backup mode male BACKUP EJ lt ON green BACKUP EJ ON green Control system ol Sols NColars
148. for connecting the network cable Turn on the Standby System s Power Supply 1 Match the position of the standby system CPU module s RUN STOP switch with that of the TRACKING CABLE 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 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 REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Confirming the Network Module Status Confirm that the new network module has not developed an error by using the System Monitor of GX Developer Start standby system Diagram 8 31 Network Module Replacement Procedure REDUNDANT SYSTEM FUNCTIONS POINT When the standby system is powered OFF the control system CPU module develops ina 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 REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS o e o zZ O O ol w l D 2 O hA 8 3 Replacing Module in Redundant System 8 44 8 3 5 Network Module Replacement Procedure 8 TROUBLESHOOTING 8 45 MELSEC TE cries 8 3 6 Main Base Unit Replacement Procedure 1 Main
149. 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 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 QJ71PB92V Sold separately Manual Number Model Code SH 080006 13JL86 SH 080007 13JL87 SH 080009 13JL88 SH 080010 13JL89 SH 080008 13JF89 SH 080394 13JR64 SH 080572ENG 13JR84 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 redun
150. from network module on extension base unit Network Module CPU Module 5 69 Executes auto refresh 5 4 Operation Mode Change Function In Backup Mode Control System Standby System a During Normal During Stop Error Executes system switching During Normal RUN and During Continuation During Stop During Stop Error Error 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 Does not execute input Does not execute output Does not execute Executes the function j output it Executes the function Does not execute auto refresh Does not execu
151. i F AR zg E 5 System A 3 d If the CPU module connected to GX Developer is E Z g 4 aF system B communication is done with the other Tracking cable u system system A via the tracking cable N S Communicate with the System A s CPU module GX Developer System A Control System System B Standby System me s mm c g Select this option to communicate with system B System B i E E i a o x B el il 2 CPU module using GX Developer HHS B n If system switching occurs communication A Tracking cable S35 F ES OF continues with the new system B CPU module O2 GX Developer Communicate with the System B s CPU module S System B If the CPU module connected to GX Developer is i System A Control System System B Standby System system B communication is done with that CPU module If the CPU module connected to GX Developer is system A communication is done with x T g x 2 i i Tracking cable E the other system system B via the tracking cable g 3 Se T N Communicate with the System B s CPU module GX Developer W 5 5 ao 6 1 Communication with GX Developer and PX Developer 6 2 6 1 1 Communication Methods with GX Developer 6 REDUNDANT SYSTEM NETWORKS MELSEC TE eries 6 1 2 Confirming the Connection Target on GX Developer The current communication target CPU module and the connection path can be confirmed on the following GX Developer screen Display information for the connected system in
152. made since CC Link master station does not exist For the standby master station function refer to the following manual L gt CC Link System Master Local Module User s Manual TRACKING CABLE 2 When mounting to the extension base unit Set Master station Extension base PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 2 1 System Configuration 2 9 2 SYSTEM CONFIGURATION MELSEC Aeres 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 Master station Standby Master station System A Control System System B Standby System N 2 QnPRHCPU QJ71LP21 QJ61BT11N QJ71E71 QnPRHCPU QJ71LP21 QJ61BT11N QJ71E71 QJ71GP21 SX QJ71GP21 SX 2 o 3 3 fe fe 2 2 a 2 2 e n n lt lt D D z 6 fo a oO Tracking cable CC Link Remote device Intelligent device station station Local station Remote I O stati
153. master module DeviceNet slave System System Extension via module and AS i master module Applicable Extension base units e For Ethernet modules dedicated instructions Maximum 7 stages interrupt pointers e mail function communication by the fixed buffer FTP server function web server function is not usable For intelligent function modules other than the above dedicated instructions and interrupt pointers are not usable lt lt First 5 digits of serial No is 09012 or later gt gt Applicable Extension base units Up to 7 The following modules cannot be mounted Interrupt module CC Link IE Controller Network module MELSECNET H module Ethernet module function version B or earlier Web server module first 5 digits of serial No 09011 or earlier PROFIBUS DP master module PROFIBUS DP slave module PROFIBUS DP interface module DeviceNet master module and DeviceNet slave module For intelligent function modules dedicated instructions and interrupt pointers are not usable Single CPU System Applicable Debug mode only Applicable INDEX Configuration Extension Base Unit 2 MELSECNET H 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 1
154. modules and network modules on slots 1 and Enabled network module on slot 0 later mas Applied Restriction on the A 3 The Ethernet modules and MELSECNET H applicable intelligent Not applied function modules modules of serial No 06052 or later are applicable Programming Tool Program App 7 GX Developer Instruction restriction Version 8 18U or later is applicable Instructions shown in Table App 4 cannot be used e Instructions shown in Table App 5 can be used under restrictions Version 4 or later is applicable 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 N A Appendix 2 Comparison of Qn H CPU and QnPRHCPU Applicable APPENDICES MELSEC TE eries Table App 4 Instructions Inapplicable for QNPRHCPU 2 lt x Instruction i Instruction g 2 z Instruction Name Instruction Name eae symbol symbol uw Fa PLOADP Program Load from Memory Card PLSY Pulse Output g 5 A 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
155. 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 TROUBLESHOOTING 7 1 Instructions Restricted in Use for Redundant System T 7 PROGRAMMING CAUTIONS MELSEC IA ries Refer to the following manual for details of the COM instruction and ZCOM instruction L gt MELSEC Q L Programming Manual Common Instruction eeeeeeeveeeeeeseeeeeeeoeeeeeeeeeeeeeeeeeeeeeeeeeeeeee eee 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 eeeeeeeveeeeeoeseeaeeeeeoeeeeeeeeeeseeeeeeeeeeeaeeee ee ee 8 For the dedicated instructions for the intelligent function module refer to the manual for the intelligent function module to be used Ts 8 7 1 Instructions Restricted in Use for Redundant System PROGRAMMING CAUTIONS MELSEC TE cries 7 2 Cautions on Fixed Scan Clocks and Fixed Scan Execution Type Programs OVERVIEW 1 Fixed scan Clocks SM409 to SM415 When system switching occurs fixed scan clock measurement is suspended until system switching is complete When syste
156. nearest Mitsubishi represenative reseller or branch office and explain the fault symptoms Please contact the nearest Mitsubishi represenative reseller or branch office and explain the fault symptoms Is there a hardware failure Clear the fault and reset with the RESET L CLR switch Please contact the nearest Mitsubishi Does the RUN LED light up represenative reseller or branch office and explain the fault symptoms Completed Diagram 8 6 Flow for the Case where the System A System B CPU Module RUN LED is not ON 8 1 Troubleshooting Flow 8 1 4 When the System A System B CPU module RUN LED is not ON 8 TROUBLESHOOTING M ELS 26 Fel ceries 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 OVERVIEW A system switching has occurred Connect GX Developer to the control system CPU module and check the error log using the System Monitor PLC diagnostics CONFIGURATION SYSTEM Does the control system CPU module s error log contain CONTROL EXE error code 6200 A system switching has not occurred TRACKING CABLE Monitor the system switching cause using GX Developer PLC diagnostic error log and reviewing details for CONTROL EXE error code 6200 REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A YES Turn ON
157. 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 Table5 62 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 Module mounted on main base unit including Redundant CPU Module mounted on remote I O station 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 5 129 5 10 Redundant CPU Functions Restricted in Redundant System 5 10 1 Enforced ON OFF of external I O D REDUNDANT SYSTEM FUNCTIONS MELSEC KE eries 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 OVERVIEW However when the control system is powered off the control system CPU module is reset the master station
158. o ooo000 ooo ooo b ooo000 a I Eee Tracking cable Diagram App 15 The system when System B is operating as the control system Appendix 5 Method for Starting up the Previous Control System App 26 APPENDICES MELSEC A ni 2 Power supplies of both systems are temporarily OFF because of a power failure etc ooo000 ooo ooo000 ooo System A System B l El E EA ji off j l ll is JEL Tracking cable 1 Power ON OFF Power ON OFF Diagram App 16 The system when power supplies of both systems are temporarily OFF 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 J SP CONTSW K1 MO GOEND GOEND Control system Standby system System A System B oo0000 ooo ooo000 ooo
159. of redundant CPU operation Upon an error detection the redundant CPU stops the operation and performs system switching 7 The redundant CPU holds all outputs Y that have not been assigned to the Z main base unit while it processes the outputs Y that have been assigned to 5s W Ww the main base unit according to Output Mode on Error Detection of the PLC TE 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 g Output of modules set to Maintain output is held Device memory output o rA Y is maintained Bo o gt 2 Continuation of redundant CPU operation a Upon an error detection the redundant CPU executes all programs other than the program instruction where the error occurred p 2 i 3 e 5 1 Basic Concept of Redundant System 5 26 5 1 5 Self Diagnostics Function D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series 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 instruction error setting for extension in future 3 Blown fuse 5 Intelligent program execution error 4 Module verify error 6 File access error 7 Memory card operation error 8 Extern
160. on that page and the convenient information eeeeeeevneeveeeeseeaeoeeeeeeeeeveeeeeseeeoeveeseeeeeeeeeeeeee eee e A 19 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 High Performance model QCPU Process CPU Redundant CPU Universal model QCPU QCPU QnCPU QnHCPU QnPHCPU QnPRHCPU QnUCPU Q Series GX Developer OPS CC Link IE Controller Network module MELSECNET H MELSECNET H module MELSECNET 10 Ethernet Ethernet module CC Link CC Link master module Q30B Q3SOB Q3ORB Qa50B Q60B Q6ORB Q60OWRB Main base unit A 20 Generic term for the QOOJCPU Q00CPU and Q01CPU Generic term for the Q02CPU Q02HCPU QO6HCPU Q12HCPU and Q25HCPU Generic term for the Q02PHCPU Q06PHCPU Q12PHCPU and Q25PHCPU Generic term for the Q12PRHCPU and Q25PRHCPU Generic term for the QOOUJCPU QOOUCPU Q01UCPU Q02UCPU Q03UDCPU Q04UDHCPU QO6UDHCPU Q10UDHCPU Q13UDHCPU Q20UDHCPU Q26UDHCPU QO3UDECPU QO4UDEHCPU QO6UDEHCPU Qi10UDEHCPU Q13UDEHCPU Q20UDEHCPU Q26UDEHCPU Q50UDEHCPU and Q100UDEHCPU Generic term for the Basic model QCPU High performance model QCPU Process CPU Redundant CPU and Universal model QCPU Another name for the Q02CPU Generic term for the QO2HCPU QO6HCPU Q12HCPU and Q25HCPU Generic term for the QQ2PHCPU QO6PHCPU
161. 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 CONFIGURATION SYSTEM 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 TRACKING CABLE 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 output changes according to device Y Output The external output changes according to device Y REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol 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 r
162. or earlier using a memory card storing network parameters for Ethernet and CC Link configurations on an extension base unit e Do not disconnect the extension cable while the power supply module mounted on the main base unit is ON e Any dedicated instructions cannot be used to intelligent function modules on extension base units lt 37 Section 7 1 8 e Any interrupt pointer caused by an interrupt from an intelligent function module on an extension base unit cannot be used K Section 7 5 4 Connect extension cables so that an overall cable distance does not exceed 13 2 m 43 31 feet 1 To calculate an overall cable distance use the longer length for the two extension cables connecting between the system A or B main base unit and the redundant type extension base unit Example System A extension cable 1 5 m 4 92 feet System B extension cable 3 m 9 84 feet System A System B z J z Ae i JHS Q JET System A extension cable System B extension cable 3 m 9 84 feet 1 5 m 4 92 feet mE Extension cable 2 m 6 56 feet bot Extension cable 5 m 16 40 feet 3 2 5 10 m 32 81 feet lt 13 2 m 43 31 feet 2 18 2 4 System Configuration Cautions 2 SYSTEM CONFIGURATION MELSEGC TE eries
163. 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 that makes auto refresh setting to the CC Link master module on the extension base unit PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM REDUNDANT SYSTEM FUNCTIONS 4 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 REDUNDANT SYSTEM NETWORKS bas z o a g OF o3 E ao TROUBLESHOOTING 7 5 Precautions of Programming when Connecting Extension Base Unit T 23 8 TROUBLESHOOTING MELSEC TA eries CHAPTER8 TROUBLESHOOTING This chapter provides troubleshooting methods of redundant system Error codes special relays and special registers of redundant CPU are not covered in this manual Refer to the following manual for error codes special relays and special registers of redundant CPU L gt QCPU User s Manual Hardware Design Maintenance and Inspection The CPU module status can be confirmed by the LEDs which are situated on the front face of the CPU module The CPU module LEDs necessary for troubleshooting of redundant system are explained here
164. power off being reset D standby system stop error tracking cable disconnection are removed the system switching may z 2 occur gt Table5 28 to Table5 32 z 3 Watchdog timer error corresponds to the WDT ERROR error code 5000 OR 5001 D m 4 The control system switches to the standby system but the standby system status does not change o zZ F a PL zZ E a E if a 5 oO 5 3 The System Switching Function 5 44 5 3 3 System Switching Execution Possibility D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries Table5 27 Operating Status and Details Operating Status Description Normal 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 Error The CPU module is in the RUN STOP and PAUSE status where a continuation error has occurred Stop Error The CPU module has stopped as a stop error has occurred Power Off The system power is OFF Resetting The CPU module is being reset At network fault detection A fault has been detected by at least one module of standby system network modules CC Link IE Controller Network module MELSECNET H module Ethernet module PROFIBUS DP master module Preparing for Tracking The communication is not made between the control system and standby system via tracking cable System Switching Request Timeout Executing System Switching
165. previous system switching condition Table5 35 Operations When System Switching Cannot Be Executed Due to Operation mode i e Separate Mode System Control System Switching Condition Switching Method System Status After System Switching Condition System A System B System A System B Before System Switching Operation After Changing From Separate Mode to Backup Mode Stop Error Other Than Control Standby Control Standby ae System switching will not be executed Watchdog Timer Errors System System System System Control Standby Control Standby oo Watchdog Timer Error System switching will not be executed System System System System Cannot change from Separate Mode to Control Standby Control Standby Hardware Failure Backup Mode due to a control system System System System System hardware failure Automatic Cannot change from Separate Mode to System Control Standby Control Standby maple Power OFF Backup Mode due to control system Switching System System System System power OFF Cannot change from Separate Mode to Control Standby Control Standby Reseting Backup Mode due to control system System System System System reset status System Switching Control Standby Control Standby A A Request by Network System switching will not be executed System System System System Module System Switching Control Standby Standby Control oe System switching will not be executed Manual Using
166. 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 Diagram 7 1 shows the system configuration for the example of the REMEFR instruction programming Control system Standby system a oF o o a e ooo T Station No 10 j Te a wel al yy Target intelligent function module of REMEPR instruction I O No 10H Diagram 7 1 System Configuration eoe e Relevant devices Table7 2 indicates the devices used in the program example for the REMER instruction Table7 2 Devices Used for Execution of REMFR Instruction Device No Name Remarks SB20 Module status Refer to the following manual for details of SB47 Baton pass status of host the link special relays SB and link special SB48 Status of
167. refresh Does not execute auto refresh o zZ o 6 ra 20 2 Z E ie 0 Be A im l a 2 fe ad 5 4 Operation Mode Change Function 5 70 REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries Table5 42 Operations After Operation Mode Change Continue In Backup Mode Control System Standby System ee During Normal During Normal RUN and During During Stop RUN and During During Stop During St ee Error During Stop Continuation Error Continuation Error Error Executes a refresh from the network module to the CPU module Executes the Does not execute a refresh from the function CPU module to the network module Refresh between CC Link IE Controller Network CPU Executes the function Module Network Module Transient Requested from Other Station in CC Link IE Controller Executes the function Executes the function Network Refresh belwecn MECSECNETA pase A Executes the PLC to PLC Network CPU Executes the function i Does not execute a refresh from the function CPU module to the network module Module Network Module E t t Transient Requested from Other ino r Station in MELSECNET H PLC to Executes the function switching Executes the function PLC Network Input from MELSECNET H Remote I O network Input Refresh from Network Module to CPU Module Output to MELSECNET H Remote T OFF output I O net Output Refresh From CPU Outputs it ae oupa Does not output it Mo
168. s Manual Function Explanation Program Fundamentals 10 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 MELSECNETH 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 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 16 For details of the MELSECNET H network system refer to the following manual LQ Corresponding MELSECNET H Network System Reference Manual PLC to PLC network 6 25 6 2 Redundant System Network Overview 6 2 2 MELSECNET H Remote I O network
169. signal to ON Set refresh update request signal to OFF Set control program execution flag to ON End main routine program Set CC Link forced master switching flag to ON End interrupt program APPENDICES MELSEC KE eries 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 APPENDICES Step 2 to 18 Diagram App 8 Sample program overview flow INDEX 2 Sample program SM402 0 HR o gt pee M100 X40 X4F X41 SB47B M100 _ A ASs 1031 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 P1 Control CC Link A E ee ee PEE E N E E E EA EE EA END Diagram App 9 A sample program of MAIN Appendix 4 Sample Programs when Using CC Link App 22 Appendix 4 5 Sample Program APPENDICES MELSEC Le ceries 2 When the QJ61BT11N s serial No first 5 digits is 07111 or earlier a Sample Program Name CHANGE 1 Sample program overview flow CHANGE 141 Set 141 to be valid Step 0 to 11 Forcibly change the system that communicates with the CC Link Step 71 to 73 IRET Initialize devices at the time of system switching Step 12 to 16 Refresh the remote devices
170. standby system CPU modules to keep them consistent 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 Section 5 6 1 e Writing to the CPU module that is running gt Section 5 6 2 5 6 1 Writing to the CPU Module in STOP Status 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 Standby system Control system fz l fs I E al E HIE a e 5 l z Bj fa J e f am E gt a a u a l g 5 mm 6 a LAJ c a i am g 2 Perform PLC write to standby CPU module I 1 Perf
171. 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 whether 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 o Multiplexed Remote Master Station Point B D are simultaneously Sub master Station station No 0 disconnected station No 1 Standby Control system system pi D al f e al B m E 6 g al J Ee El fai e E B al lal ial e g Tracking cable Point B
172. stop i o X 0 Delay infomation setting Station information setting Station information Remote device station initial setting _fritiatsettings Interrupt setting Interrupt settings a Indispensable settings No setting Already set Setifitismeeded No setting Already set Setting item details Acknowledge XY assignment Clear 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 Link system including reserved stations to 4 Systems Appendix 4 Sample Programs when Using CC Link App 18 Appendix 4 4 Parameter Settings APPENDICES MELSEC TA eries 6 Special Relay SB Set the special relay SB refresh device to SB400 Special relay SB Special Register SW Set the special register SB refresh device to SW400 Special register SW 7 8 Retry Count Use the retry count for communication errors to 3 Default 9 Automatic Reconnecti
173. stored by user or system Register Table5 47 O a 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 x O x PID Control Instruction PID control data specified by PIDINIT and data S PIDINIT instructions O O A 41 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 flow 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 44 When changing the number of the device points to be used in the PLC parameter device setting using GX Developer the number after change will be the tracking range By default all device points in the tracking range are to be tracked 5 77 5 5 Tracking Function 5 5 3 Tracking Data D RE
174. the END instruction is executed with SM50 ON 2 Clearing the Standby System CPU Module Error by the Control System CPU Module A standby system CPU module error is cleared with the user program of the control system CPU module using SM1649 and SD1649 When using GX Developer connected to the control system CPU module to clear a standby system CPU module error SM1649 and SD1649 are also used a Procedure Error clear is performed according to the following procedure module 4 The target error is cleared from the standby system b Cautions 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 3 Turn SM1649 in the control system CPU module from OFF to ON 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 Operation Mode Backup Mode CPU Module Performing Error Clear Control System CPU Module Standby System CPU Module O x Separate Mode x x Debug Mode Standby System Error Clear Enabled x Standby System Error Clear Disabled Irrelevant as Standby Syst
175. the control system Start up system A as the control system If CC Link system master module is mounted on the main base unit system B cannot start as the control system If all stations are faulty in CC Link network system A system will be control system since Xn1 does not turn ON To start with the previous control system power ON the programmable controller CPU after powering ON the CC Link remote I O stations To use the Rise Fall execution instruction in a program of B system after system switching set Do tracking at Signal flow memory tracking setting on Tracking settings in redundant parameter App 31 Appendix 5 Method for Starting up the Previous Control System APPENDICES MELSEC TE cries 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 PROCESSING TIME FOR REDUNDANT SYSTEMS The dedicated instruction applicable in the serial communication module and the changeability by the FROM TO instruction are shown in Table App 13 APPENDICES Table App 13 Serial Communication Module Dedicated Instruction List Changeability by Instruction g g E nime Function overview FROM TO Re
176. the control system z resets both systems Both systems are reset also when Currently specified station is selected at the execution destination area on the Remote operation screen of GX Developer zZ O Control STOP Standby STOP 5 system system g g a m m 26 nO a 5 i Tracking cable a a q S o zZ x O GX Developer z z x Control STOP gt Reset Standby STOP gt Reset oe 2 Remote operation system system in 2 Connection target information Be Z Connection interface COMI lt gt PLC module g 5 im S B a A E Target PLC Station no Host PLC ype Q25PRH p A 3 c a PLC status RUN 2 A D X Systembpe Canclaytem Operation mode Backup mode al HJ 5 Operation Specify execution destination Tracking cable cre a Currently specified station C Allstations C Specific group 7 C Extract memory card GX Developer Lu E wn gt wn i Zz lt x Q a W X o Z O O Z Le Control Reset STOP Standby Reset STOP fi system system L E N 2 E 3 B 8 I ele e O fe tml a a a g Q ey ete OU eaga e Tracking cable o o GX Developer S65 95 Diagram 5 101 Remote Rese
177. 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 tracking 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 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 eeeee ecsesceaeaeeaoeeeoeeeoeoeeecoeeceeoeoeeeeoeeeoeoeoe eae eeeoeoeeeea eee 5 5 Tracking Function 5 74 5 5 1 Tracking Function Overview OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUN
178. unit for redundant system Mount them to the remote I O station or extension base unit in the MELSECNET H Remote I O network 6 2 Redundant System Network Overview 6 REDUNDANT SYSTEM NETWORKS M IES 26 FY caries OPS Personal computer a Ethernet fe C CC Link IE Controller Network D Multiplexed Remote Master Station Multiplexed Remote Sub master Station QCPU QCPU QCPU System A Master station System B Standby Master station Donne oie pair Z Control System Standby System Station Station staton E a S fz a 8 al a e a O a l gl al g Lu TE 7 pA l a 2 HA ll ne j al A E DP Slave DP Slave F E Oy
179. z O T 5 o Le Z Q SYSTEM a Modules mountable to main base unit where redundant CPU is mounted Table2 1 lists the modules mountable to a main base unit where a redundant CPU M is mounted a Table2 1 Modules Mountable to Main Base Unit Where Redundant CPU is Mounted 9 Module Name Model Checking Method 5 Q61P A1 Q61P A2 Q61P Power supply module 1 Q62P y fi Q63P Cae Q64P ESE Soa Q64PN T Z Z 2 7 Q63RP o a Redundant power supply module lt Q64RP ono Q12PRHCPU CPU module 3 Q25PRHCPU CC Link IE Controller Network module 8 ube Oe QJ71GP21S SX 2 QU71LP21 25 42 QJ71LP21S 25 55 MELSECNET H module 6 QJ71LP21G Feinn tR QJ71LP21GE QJ71BR11 e QJ71E71 B2 fag Ethernet module 6 7 QU71E71 B5 2 e QJ71E71 100 5 9 CC Link master module 4 67 QJ61BT11N Serial No first 5 digits 06052 or later S PROFIBUS DP master module QJ71PB92V Function version D 5 D 5 Input module 7 QX a Output module 7 QY 8 7 QH42 I O combined module QX48Y57 gt g 1 Mountable only when the Q32B Q33B Q35B Q38B or Q312B is used 2 2 Mountable only when the Q38RB is used 5 er indicates the type of the input module or output module eS 4 The QJ61BT11 cannot be mounted on a main base unit where a redundant CPU is mounted 5 For checking of the serial No and function v
180. 00 to 3107 2 28 Remote password check REMOTE PASS ERR 3400 3401 Z 29 Intelligent parameters check SP PARA ERROR 3300 to 3302 z z 30 File consistency check FILE DIFF 6000 9 E 31 Parameter valid drive settings consistency check FILE DIFF 6001 ES 32 Tracking setting parameter check TRK PARA ERROR 6500 6501 41 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 a 2 The errors may be detected regardless the priority 3 3 Can be changed to continue in the PLC parameters settings of GX Developer o z g 5 1 Basic Concept of Redundant System 5 28 5 1 5 Self Diagnostics Function D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG Q series 5 1 6 Start Mode 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 Select Initial start mode Hot start mode Redundant parameter Operation settings Tracking settings Start mode setting Mode Initial start mode It will become Hot start mode during system switching Standby system watch setting IV Check the error in Standby system Debug mode setting
181. 000000000000000000000000000000000000000000000000000000000000000000000000000 22 CHAPTER1 OVERVIEW 1 1to1 16 1 1 Redundant System OvervieWwe ececccccccooo000000000000000000000000000000000000000000000000000000000000000000000 4 1 2 Features cooocoooooooooooooooooooooooo000000000000000000000000000000000000000000000000000000000000000000000000000000000 6 CHAPTER2 SYSTEM CONFIGURATION 2 1to2 22 2 1 System Configuration cooococoooooooooooooooooooooo00000000000000000000000000000000000000000000000000000000000000000 1 2 2 Peripheral Device Configuration COCO OOOO OOOO OOOO OOOO OOOO OOO OOOO OOO OOO OOOO OOO OOOO OOOOH OOOO HOO OOOOO OOOO OOOO OOOO 2 12 2 3 Applicable Devices and Software COCO OO OOOO OOO OOOO OOO OOO OOOOH OOOO OOO OOOOH OOOO OOO OOOO OOO OOOO OOOOO OOOO OOOOOOOOE 2 13 24 System Configuration Cautions COC COO OOOO OOO OOOO OOO OOO OOOO OOO OOOO OOO OOO OOOO OOO OOOO OOO OOOOS OOO OOOO OOOO OOOO OOOOE 2 18 CHAPTER3 TRACKING CABLE 3 1to3 4 3 1 Specifications COC COOOO OOO OOO OOOO OOO OOOO OOO OOOO OOOO OOOO OOS OOO OOOO OOO OOOO OOOOH HOO OOOO OOO OOOO OOO OOO OOOO OOO OOOO OOOOOOOOOS 3 1 3 2 Part Names 00oooooooooooo00000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 3 1 3 3 Connecting and Disconnecting a Tracking Cable ecccccocoooooooooooooooooooo000000000000000000000000000000 3 2 CHAPTER4 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM 4 1to4 17
182. 1 Remote reset operation coooooooooooooooo000000000000 D 134 Remote RUN eeeescoc00000000000000000000000000000000 D 131 Remote STOP eeeccecccccccccccccccccccccccccccccccccses 5 31 Restarting system A and system B seseeseeeeseeseee 4 15 Restrictions on online module change Hot Swapping REVISIONS ccccccccccceccccccccccccccccocccccocccccccoeces A O Running CPU modules eccececcccccccccccccccccccccccee 1G S Same system network module No issuing system switching request COCOCOCOCOCOCOOCOOCOOCOCOOOOOOCOOOOO0000000000000O 5 54 SD1588 eeesseesscecsceccooessecsosecsoccsoocsseessoeesee 5 54 SD1589 eeesseesseecsceccooesseessoecsoecsoocsseessseesee 5 54 SD1590 eeesseesscecsceccooessecssoccsoecsoocsseessseesoe 5 54 SD1595 eesceeeesscooecsscooecsscooeeoscoooeosesooooses 5 112 SD1596 eeeseeeesscooecsocooecsscooeeossoooeesssoooosos 5 112 SD16O0 eeesseesscecseeccoocsseesssecsocccoossseessseesse 5 55 SD1601 ecccccceccccccccccccccccccccccccccccsccsesesseseeee 5 55 SD1602 eccccccecccccccccccccccsccccccccccccccesccessoseeee 5 55 SD1610 cccccccecccccccccccccccsccccccccscccscesesessoseeee 5 55 SD1709 ccecccccccccccccccccccccccccccccccccccsscsecceses 5 106 Self diagnostics at startup of redundant CPU 5 28 Self diagnostics FUNCTION ccccccccccccccccccocccccseccee 5 26 Separate MOE cecccccccccccccccccccccccccccccccccccccces 5 Setting the debug MOE eecccccccccccccccccccccccccecee A Settings of operation mode for error occurrence SEC data
183. 3 Ml 3 ao 5 1 Basic Concept of Redundant System 5 16 5 1 4 System Consistency Check D REDUNDANT SYSTEM FUNCTIONS Table5 10 Consistency Check Execution Conditions between System A and System B MELSEC TA eries Conditions 1 Description Standby Control Param ter Execution Operation System System Operating Basic System Memory Card A j Pe F z 5 3 Valid Drive Timing Mode Operating Operating Status Configuration Settings Settings Status Status 7 Standby Syst Control Syst gt ee Y ue ig ene ve st Operating Basic System Memory Card Parameter Valid Execution Timing Operation Mode Operating Operating File i Status Configuration Settings Drive Settings Status Status Both systems powered on Backup Mode O O G O O simultaneously Both systems Unreset 3 Backup Mode O O O O O simultaneously RUN oO O STOP RUN PAUSE O STOP RUN O O RUN STOP STOP O PAUSE PAUSE Backup Mode STOP RUN O al al END processing RUN O O i STOP RUN STOP PAUSE O Power ON RUN O O Q O STOP Unreset PAUSE O O O Pare RUNI RUN O O O O anging Mom l STOPS RUN Separate Mode p ON STOP to Backup Mode N 3 PAUSE R O O O Unreset 3 RUN RUN O O O O Tracking cable Backup Mode Son RUN reconnected STOP O O O PAUSE PAUSE 5 17 5 1 Basic Concept of Redundant System 1 The consistency check is executed only in
184. 3 8 1 Troubleshooting Flow 8 1 5 When System Switching has Occurred 8 TROUBLESHOOTING M eLS 26 Q ceries 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 OVERVIEW 1 In the Case of System Switching by GX Developer Systems did not switch CONFIGURATION SYSTEM 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 TRACKING CABLE Did the switch occur YES normally REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Completed Check again following the 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 REDUNDANT SYSTEM FUNCTIONS Diagram 8 8 Flow for the Case where System Switching Has Failed REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS o e o zZ O O ol w l D 2 O hA 8 1 Troubleshooting Flow 8 14 8 1 6 When System Switching has failed TROUBLESHOOTING MELSEG Fl aries 2 In the Case of System Switching due to Control System Error o
185. 3 Flowchart for when SP UNIT DOWN Occurs 8 25 8 1 Troubleshooting Flow 8 1 12 When SP UNIT DOWN Occurs 8 TROUBLESHOOTING M eLS 26 Fel ceries 8 1 13 When SP UNIT LAY ERROR Occurs The following shows the flowchart for when SP UNIT LAY ERROR occurs during ai operation of the redundant system i An error message SP UNIT LAY ERROR was detected Zz O E ao p nz SO YES se Are three or more CC Link Reduce the number of mounted CC IE Controller Network Link IE Controller Network modules modules mounted to two or one Lu a 3 NO g x O Are five or more CC Link IE YES Reduce the number of mounted CC Link z Controller Network modules and IE Controller Network modules and x 5 MELSECNET H modules MELSECNET H modules to four or less z D mounted in total in total g z z RE Sta Tbe NO Lu D Are five or more YES Reduce the number of mounted 7 MELSECNET H modules MELSECNET H modules to four or less 22 mounted ao 55 az NO rare YES ai Are five or more Ethernet Reduce the number of mounted Ethernet modules mounted modules to four or less gt zg aon zO NO 35 WW Ww ez NO i Are the parameter contents Rewrite the network parameters normal o Ss YES z 2 95 A hardware failure occurs to the CPU Be module Consult your local Mitsubishi representative explaining a detailed description of the problem o e Dia
186. 4 8 CONFIGURATION SYSTEM 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 Complete Diagram 4 1 Procedure for starting Up in Backup Mode TRACKING CABLE A 14 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 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 Ethernet diagnostics CC IE Control diagnostics MELSECNET diagnostics and CC Link CC Link LT diagnostics
187. 402 ON for 1 scan only after RUN a SM1515 Control system judgment flag Control system SM1515 ON SM15165 OFF a SM1516 Standby system judgment flag Standby system SM1515 OFF SM1516 ON lt 5M1518 Standby system to control system switching status flag PE OFF Manual switching prohibited SM1592 Enable manual system switching flag ON Manual system switching enabled OFF trol ti t ibl M100 Enable control program execution flag A OTAR Ion ve ee ON control program execution possible OFF syst itchi t not b ted x lt M101 System switching execution flag SSe ja 2 mg Dee en ee fal ON system switching executed 2 M102 System B first startup system switching flag OFF system switehing must not beexecuted ON _ system switching executed OFF I M202 SP CONTSW instruction error flag lis ON error OFF Not ted data link M4531 During data link execution i Srecu i hes y 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 b ter station in CC Link t 141 Pointer performed at STANDBY error pues an Puneet anes ee the master station 2 CC Link Master Local Module Devices Table App 11 CC Link Master Local Module Devices Device Number Application R
188. 5 81 SD207 to SD209 LED display priority ranking SD210 to SD213 Clock data SD250 Loaded maximum O D315 Time reserved for communication processing D414 2n second clock setting D415 2n ms clock setting SD550 Service interval measurement module SD774 to SD775 PID limit setting for complete derivative D778 Refresh processing selection with the COM instruction is executed SD794 to SD795 PID limit setting for incomplete derivative D1500 to SD1501 Basic period D1649 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 M IRS 26 Fel ceries 5 5 4 Tracking Data Settings Make the tracking data settings at Tracking settings in Redundant parameter in GX ai Developer a ii 5 If no tracking settings are made by the user Tracking device settings will be set to Internal device block setting default and tracking will be executed based on Default Tracking Range in Table5 44 in Section 5 5 3 1 1 g Redundant pzrameter mS Operation settings Tracking settings m z 2 Tracking device settings Internal device block setting x Internal devices include Y and other internal devices Signal flow memory tracking setting 6 e No tracking All tracking device capacity K word C Do tracking Device total in
189. 6 REDUNDANT SYSTEM NETWORKS MELSEC TE eries 6 2 3 Ethernet External devices use MC protocol fixed buffers random access buffers data link instructions etc to communicate with the CPU modules of a redundant system OVERVIEW Partner products including EZ Socket can also communicate with them through OPS connection Refer to the following manual below for details Q Corresponding Ethernet Interface Module User s Manual Basic 1 Indicates the FA communication middleware for programmable controllers servos robots NC etc made by Mitsubishi Electric which consists of the Windows API Application Programming Interface By using EZ Socket each partner company can easily develop FA related application CONFIGURATION SYSTEM software using FA devices made by Mitsubishi Electric which operate on Windows personal computers POINT Ethernet module can be mounted to the main base unit or extension 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 unit TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM FUNCTIONS ez W wn gt n j A Ed a Zz fa W a n X x e z E W zZ PROGRAMMING CAUTIONS TROUBLESHOOTING 6 2 Redundant System Network Overview 6 26 6 2 3 Ethernet 6 REDUNDANT SYSTE
190. 8 1 Troubleshooting Flow 8 1 10 When BASE LAY ERROR Occurs 8 TROUBLESHOOTING M ELS 26 Q ceries 8 1 11 When UNIT LAY DIFF Occurs The following shows the flowchart for when UNIT LAY DIFF occurs during operation of ai the redundant system i 5 Error message UNIT LAY DIFF was detected fe E 20 BS Is error code 6030 YES ao NO Are module mounting Constitutions of control system and Module mounting status of control system l and standby system should be the same 2 standby system of redundant S system the same 2 g O Are mode settings of systems Set the mode setting of system B the re A and B of network module the same same as mode setting of system A in 2 lt Redundant settings of network parameter ws 5 8 amp 2 erw YES ange YES Since the CPU model name differs Is error code 6035 between control system and standby m system in redundant system use the s same one e 22 a6 ZE DOG az rare Check to see if network cable is not a broken since remote I O constitution of D Is error code 6036 MELSECNET H multiplexed remote I O a network differs between control system and 5 g standby system in the redundant system t 5E Q NO rz Hardware failure of the following modules is suspected o CPU module Main base unit or extension base unit 29 Extension cable 9 Operate the systems sequentially from the minimum o5 are z
191. BUS DP master module PROFIBUS DP slave module PROFIBUS DP interface module DeviceNet master module DeviceNet slave INDEX System System expansion using module and AS i master module Configuration extension base units Applicable Extension base units e For Ethernet modules dedicated instructions maximum 7 levels interrupt pointers e mail function communication by the fixed buffer FTP server function web server function is not usable For intelligent function modules other than the above dedicated instructions and interrupt pointers are not usable lt lt First 5 digits of serial No is 09012 or later gt gt Applicable Extension base units Up to 7 e The following modules cannot be mounted Interrupt module CC Link IE Controller Network module MELSECNET H module Ethernet module function version B or earlier Web server module first 5 digits of serial No 09011 or earlier PROFIBUS DP master module PROFIBUS DP slave module PROFIBUS DP interface module DeviceNet master module and DeviceNet slave module e For intelligent function modules dedicated instructions and interrupt pointers are not usable 41 MELSECNET H 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 r
192. CAUTIONS TROUBLESHOOTING 1 11 1 OVERVIEW MELSEC LAY ceries 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 also be done via special relays and special registers C Section 5 7 n Failed CPU module GX Developer 2 Transfer Standby Control system system N g En I T ma a ooo000 nooo Haa E ee imal RE j w jeje Send parameters programs H Tracking cable B J Fa NGXO NE Nexo Ear ojo 0 EAN 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 12 1 2 Features 1 OVERVIEW MELSEC TE eries 7 Access to redundant system from host network
193. CNET H Remote I O network Remote I O station Remote I O station Remote I O module Serial communication module ecoles When specifying System A using MC protocol Diagram 6 32 Communication with System A CPU Module by MC Protocol 6 41 6 2 Redundant System Network Overview 6 2 5 Serial Communication Modules 6 REDUNDANT SYSTEM NETWORKS M als 26 fel ceries 6 2 6 PROFIBUS DP 1 Communication overview of the PROFIBUS DP ai In redundant system when the PROFIBUS DP master module detects a fault or i r communication failure with DP Slaves the standby system maste
194. CONFIGURATION M als 26 fel eries 3 Communication via CC Link IE Controller Network or MELSECNET H PLC to PLC Network OVERVIEW a Connecting Redundant System to CC Link IE Controller Network MELSECNET H and MELSECNET 10 PLC to PLC Network A redundant system can communicate with Q series CPU modules connected to CC Link IE Controller Network or 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 z O T 5 o Le Z Q SYSTEM b Pairing Settings and Relevant CPU Modules Pairing settings must be made using the control station network parameters when connecting a redundant system to CC Link IE Controller Network MELSECNET H or MELSECNET 10 The following CPU modules include the network parameters for paring settings Redundant CPU 1 High Performance model QCPU 1 Process CPU Basic model QCPU e Universal model QCPU e Q4ARCPUs 1 2 S When connecting a redundant system to a network set any of the above CPU modules as the control station CPU modules other than above can be set as the normal station only Refer to the following manuals for details on pairing settings for CC Link IE Controller Network MELSECNET H and MELSECNET 10 PLC to PLC networks CC Link IE Controller Network Reference Manual L gt Q Corresponding MELSECNET H Network System
195. CTRIC 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 When applying the program examples introduced in this manual to the actual system ensure the applicability and confirm that it will not cause system control problems CONTENTS SAFETY PRECAUTIONS ssceccccoo0000000000000000000000000000000000000000000000000000000000000000000000000000000000000000000 A 1 CONDITIONS OF USE FOR THE PRODUCT eccccooo000000000000000000000000000000000000000000000000000000000000000000 A 8 REVISIONS COCO COOOL OOOO OOO OOOO OOO OOOO OOO OOOO OOO OOO OOOO OOO OOOO OOO OOOO OOOO OOO OOOOH OOOO OOOO OOOO OOS OOOO OOO OOOO OOOO OOO OOOOSOOOOOOOO A 9 ABOUT MANUALS ccocoooooocoooooooooooooooo0000000000000000000000000000000000000000000000000000000000000000000000000000000000 15 HOW TO USE THIS MANUAL seccccccoooo000000000000000000000000000000000000000000000000000000000000000000000000000000000 17 HOW THIS MANUAL IS ORGANIZED ecccccccccccccccccccccccccccccccccccccccvcccccccccccccccccccccccccccccccccocooosoooes A 18 GENERIC TERMS AND ABBREVIATIONS ccoooooooooocooooooooooooooo000000000000000000000000000000000000000000000000000 _ 20 RELEVANT TERMS cooococoooooooooooooooooooooo000
196. Check D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries 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 consistency check Redundant parameter Operation settings Tracking settings Start mode setting Mode Initial start mode Zi It will become Hot start mode during system switching Standby system watch setting V Check the error in Standby system Debug mode setting Do not start with Debug mode C Start with Debug mode Backup mode setting V Check operating status consistency Cancel Default Diagram 5 13 Operation setting Screen 5 1 Basic Concept of Redundant System 2 5 1 4 System Consi
197. Comparison of Q4ARCPU and QnPRHCPU App 2 System Configuration Programming Tool App 3 APPENDICES MELSEC TA eries Table App 1 Comparison of Q4ARCPU and QnPRHCPU Redundant Systems Continued Item QnPRHCPU Redundant System Q4ARCPU Redundant System 2E N A Applicable i Connection PP CPU Direct Applicable Communication with the CPU module i 3 Applicable Connection connected to the GOT only Computer Link paa ans N A Applicable Connection MELSECNET H Remote I O GOT Station Applicable N A for extension base unit N A Connection n T Connection CC Link Applicable Applicable Connection ppa PpS MELSECNET H PLC to PLC Applicable N A for extension base unit N A Network Connection Ethernet 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 Auto diagnostics error information and comments Available information and comments are displayed etc can be confirmed using GX Developer Manual System Switching Manual operational mode switching System switching by the system switching instructions or redundant operation of GX Developer Operation mode change by redundant operation of GX Developer System switching using switches of bus switching module AGRAF
198. Condition Disconnection System A System B System A System B Stop Error Other Than Control Standby Control Standby ee f System switching will not be executed Watchdog Timer Errors System System System System Control Standby Standby Standby LADEN Watchdog Timer Error System switching will not be executed System System System System Control Standby Control Standby Pare Hardware Failure System switching will not be executed Automatic System System System System System Control Standby Control Standby S R Power OFF System switching will not be executed Switching System System System System Control Standby Control Standby Pare Reseting System switching will not be executed System System System System System Switching Control Standby Control Standby ae Request by Network System switching will not be executed System System System System Module System Switching Control Standby Control Standby roe System switching will not be executed Manual Using GX Developer System System System System System System Switching by TE nee Control Standby Control Standby ee Switching System Switching System switching will not be executed iaethection System System System System ucti Table5 31 When System Switching Cannot Be Executed Due to Network Error of Standby System System Status After System System Status Before a Control System GR System Switching Operation After B Sys
199. DANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu wn gt wn Zz a a Zz 2D fa W a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series 4 Precautions Tracking transfer cannot be performed in the following cases Scan time will shorten by the tracking transfer time a The tracking cable is disconnected or is a failure TRK DISCONNECT error code 6130 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 When tracking device setting is not made the program is executed with the values before refresh at first scan after system switching Set the following devices as tracking devices e Device that makes auto refresh setting to the intelligent function module on the extension base unit with GX Configurator e Device that makes auto refresh setting to the CC Link master module on the extension base unit 5 75 5 5 Tracking Function 5 5 1 Tracking Function Overview D REDUNDANT SYSTEM FUNCTIONS M als 26 Fel ceries 5 5 2 Tracking Execution Procedure The procedure for executing tracking in Diagram 5
200. DING BUT NOT LIMITED TO ANY AND ALL RESPONSIBILITY OR LIABILITY BASED ON CONTRACT WARRANTY TORT PRODUCT LIABILITY FOR ANY INJURY OR DEATH TO PERSONS OR LOSS OR DAMAGE TO PROPERTY CAUSED BY the PRODUCT THAT ARE OPERATED OR USED IN APPLICATION NOT INTENDED OR EXCLUDED BY INSTRUCTIONS PRECAUTIONS OR WARNING CONTAINED IN MITSUBISHI S USER INSTRUCTION AND OR SAFETY MANUALS TECHNICAL BULLETINS AND GUIDELINES FOR the PRODUCT Prohibited Application Prohibited Applications include but not limited to the use of the PRODUCT in e Nuclear Power Plants and any other power plants operated by Power companies and or any other cases in which the public could be affected if any problem or fault occurs in the PRODUCT e Railway companies or Public service purposes and or any other cases in which establishment of a special quality assurance system is required by the Purchaser or End User e Aircraft or Aerospace Medical applications Train equipment transport equipment such as Elevator and Escalator Incineration and Fuel devices Vehicles Manned transportation Equipment for Recreation and Amusement and Safety devices handling of Nuclear or Hazardous Materials or Chemicals Mining and Drilling and or other applications where there is a significant risk of injury to the public or property Notwithstanding the above restrictions Mitsubishi may in its sole discretion authorize use of the PRODUCT in one or more of the Prohibited Applications
201. DO K1 J Reads the number of receive data TMOVP DO Z0 Stores the number of data read to index L register Z0 FROMP H8 H601 D1 KOZO Reads the specified number of receive data X84 X9F p 7 15 4 FROMP H8 H258 D8000 K1 J Reads the receive error code X83 22 Y81 Turns ON read completion signal Y81 X84 Diagram App 28 Program Example App 41 Appendix 6 Precautions for Using Serial Communication Module Appendix 6 3 INPUT Instruction APPENDICES MELSEC KE eries Appendix 6 4 PUTE Instruction The following shows the device and buffer memory used in the sample program of registering the user registration frame PROCESSING TIME FOR REDUNDANT SYSTEMS 1 Device of programmable controller 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 APPENDICES 2 W O signal Table App 28 List of I O Signal VO signal Signal name Description CH1 side CH2 side X n 1 8 Flash ROM write completion ON Completed 5 Q Y n 1 8 Flash ROM write request ON Requesting zZ 3 Buffer memory Table App 29 List of Buffer Memory Buffer memory address Hexadecimal decimal CH1 side CH2 side Stored value 0 No request 2 4 2 Register read delete 1 Registration request
202. DOOy Sets D1 to buffer memory length 3004 Writes receive area setting value APPENDICES MELSEC KE eries 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 PROCESSING TIME FOR REDUNDANT SYSTEMS a Device of programmable controller CPU Table App 18 Device Used in the Program Device No Application Remarks 5 X23 Receive data clear request command ON Receive data clear request o M0 Receive processing ON Executing OFF Not executed __ 2 M12 Send processing ON Executing OFF Not executed M15 Receive data clear request pulse ON Receive data clear request M16 Receive data clear request ON Receive data clear request acceptance flag acceptance M17 Receive data clear request completion ON Receive data clear request flag completion M18 Communication disable ON Communication disable M19 Communication enable ON Communication enable i b I O signal Table App 19 List of I O Signal I O signal p ER 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 n
203. DUNDANT SYSTEM FUNCTIONS MELSEC KE eries Table5 44 Internal Devices That Can Be Tracked 3 Device Default Tracking Range Tracking Range Set by User gt Input X0 to X1FFF XO to X1FFF z Output YO to Y1FFF YO to Y1FFF Internal relay MO to M8191 MO to M8191 Latch Relay LO to L8191 LO to L8191 Step Relay SO to 8191 SO to 88191 Annunciator FO to F2047 7 i Edge Relay VO to V2047 VO to V2047 fi Link Relay BO to B1FFF BO to B1FFF 58 Link Special Relay SBO to SB7FF Timer Contact Points and Current 3 TO to T2047 TO to T2047 Value w Retentive Timer Contact Points and a Current Value S Counter Contact Points and Current 5 4 CO to C1023 CO to C1023 T Value E Data Register DO to D12287 DO to D12287 Link Register 4 WO to W1FFF Wo to W1FFF Link Special Register SWO to SW7FF oe 7 Index Register ZO to Z15 ZO to Z15 u Special Relay 3 5 a S 5 Special Register 4 5 8 2 2 File Register ZRO to ZR1042431 ERE 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 reten
204. E5 010a424a gt Diagram 5 96 Error Dialog Box That Appears When Forced ON OFF Cancel Is Executed in Standby System 5 127 5 10 Redundant CPU Functions Restricted in Redundant System 5 10 1 Enforced ON OFF of external I O D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries 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 O forced ON OFF can be continued according to the forced ON OFF information registered by GX Developer before system switching OVERVIEW CONFIGURATION SYSTEM Input by forced ON OFF of external I O Registration of forced ON OFF x100 Forced ON OFF information tracked X100 ON Y120 ON Y121 0N E q H from control system CPU module or jsi ion lation XX i Control system Standby system ONOFF TRACKING CABLE GX Developer aia Output by forced ON OFF of external I O 120 0N 121 0N
205. File MITSUBISHI Program File Parameter File Parameter File MELSE MELSE 5 W D Control Standby d system system ae ERA 2 o g g E o d 3 G9 a F E a B 5 ag E LE al pojme kara E i 4 ee 18 RHE a e z z 4 B Tracking cable P z gt gt D RUN STOP Status RUN STOP Status z g Q 2 Check operating status Z z 5 Check the parameter usable drive D D z Diagram 5 11 Consistency Check Points Between Systems A and B Table5 9 Consistency Check Points Between Systems A and B Check Points Description 2 Checks parameters programs and initial device values o 1 File Contents i g Checks the memory capacity of the area for online change of multiple blocks OE 2 Operating Status Checks the CPU module operation status RUN STOP PAUSE S A Checks the CPU modules I O modules and network modules mounted on the 3 Basic System Configuration main base units Checks the set memory card setting and the type i e SRAM Flash and ATA 2 4 Memory Card Setting 5 card 9 5 Parameter Valid Drive Settings Checks the parameter valid drive settings dip switch SW2 SW
206. GX Developer System System System System System System Switching by ae te Control Standby Standby Control oo Switching System Switching System switching will not be executed inetrucion System System System System ucti 5 3 The System Switching Function 5 50 5 3 3 System Switching Execution Possibility SYSTEM PROCEDURE FOR STARTING UP A TRACKING CABLE CONFIGURATION OVERVIEW REDUNDANT SYSTEM ol Lu n gt N r Z lt a Zz a W K o Z O O Z Le REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS MELSEC TA eries 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 Program 4 Fixed Scan s Execution 2 Starts counting the interrupt interval time from 0 Refer to Execution Typ
207. H instructions 2 Read request 3 Deletion request 0 No designation 34 3 Frame No direction gnan Other than 0 Frame No 0 Normal completion Registration read delete 4u 4 Other than 0 Abnormal result storage completion 0 No designation 54 5 Number of data bytes Other than 0 Number of registered designation data bytes registered maximum 80 bytes 0 No designation 6y to 2D4 6 to 45 User frame Other than 0 Registered data maximum 80 bytes 2000 8192 Flash ROM write allow 0 Write prohibited prohibit designation 1 Write allowed Appendix 6 Precautions for Using Serial Communication Module App 42 Appendix 6 4 PUTE Instruction APPENDICES MELSEC TA eries 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 x50 0 PLS M50 E 3 MOV K MOV H3E8 MOV K10 MOV H3946 MOV H3030 MOV H3030 MOV H4646 MOV H3030 TO H8 H2000 K1 TO H8 H2 DO TO H8 H5 D3 SET M1 x98 36 an SET x98 FROM H8 H4 D2 RST RST App 43 Diagram App 29 Program Example M50 DO D1 D3 D4 D5 D6 D7 D8 K1 K2 K6 M1 Y98 K1 Y98 M1 Appendix 6 Precautions for Using Serial Communication Module Appendix 6 4 PUTE Instruction Requests registration F Sets registration request
208. H2 side Stored value 0 No request 2 4 2 Register read delete 1 Registration request instructions 2 Read request 3 Deletion request 0 No designati 34 3 Frame No direction ene Other than 0 Frame No 0 Normal completion Registration read delete 4 4 4 Other than 0 Abnormal result storage completion 0 No designation 5y 5 Number of data bytes Other than 0 Number of registered designation data bytes registered maximum 80 bytes 0 No designation 6 to 2Dp 6 to 45 User frame Other than 0 Registered data maximum 80 bytes Appendix 6 Precautions for Using Serial Communication Module App 44 Appendix 6 5 GETE Instruction 17 APPENDICES MELSEC TE cries The program example of reading the user registration frame is shown in Diagram App 30 For the I O signal is X Y80 to X Y9F x50 M1 4 PLS Mo E MOV K2 MOV H3EB X9E X9F j 4 TO H8 H2 DO SET M1 x97 er SET x97 l FROM H8 H4 D2 App 45 D2 KO RST FROM H8 H5 D3 D50 D51 FROM H8 H6 D4 frst Diagram App 30 Program Example Mo DO D1 K2 M1 Y97 K1 Y97 K1 D50 ZO KOZO Appendix 6 Precautions for Using Serial Communication Module Appendix 6 5 GETE Instruction Pulse outputs read command Sets the read request Sets the frame No to be read Writes read command etc Sets read flag Tur
209. ING UP A ol f Write Processing in Separate Mode 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 module of the system that is not specified in the connection target settings Lu wn gt wn A lt a rs D2 a W a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING 5 6 Online Program Change for Redundancy 5 98 5 6 1 Writing to the CPU Module in STOP Status D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series g Writing of CC Link parameter setting If writing to the programmable controller with setting 5 or more at No of boards in module in CC Link network parameter while the following conditions are met the error dialog box in Diagram 5 63 appears e The first five digits of serial number for the Redundant CPUs is 09101 or lower e GX Developer version is 8 58L or later MELSOFT series GX Developer i Process will be interrupted because there are no corresponding parameters for connected PLC The following causes are expected 5 or more is set in the No of boards in modules in the CC Link parameters Diagram 5 64 Error dialog box appearing on GX Developer Clicking the OK button displays the following error dialog box Replace the Redundant CPU by the one whose first five digits of serial number is 09102 or higher ME
210. L L_JL_J LI L_I program 131 TRACKING CABLE Execute Tracking transfer process i k S Tracking transfer of data after executing interrupt program Cancel tracking transfer process execute interrupt program Tracking transfer of data before executing interrupt program Diagram 7 10 Operations When Interrupt Is Executed by Internal Timer REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A When execution of programs interrupted during tracking processing is not done execute DI instructions then execute El instructions at step 0 before executing END instructions as shown in the program in the Diagram 7 11 As interrupt is disabled during END processing including tracking processing the CPU will not execute the interrupt program REDUNDANT SYSTEM FUNCTIONS 0 El H Allow interrupt REDUNDANT SYSTEM NETWORKS DI Prevent interrupt END bas Diagram 7 11 Program Example That Disables Interrupts during END Processing z o a g OF o3 E ao TROUBLESHOOTING 7 2 Cautions on Fixed Scan Clocks and Fixed Scan Execution Type Programs 7 13 PROGRAMMING CAUTIONS MELSEC TA 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
211. LC to PLC Network Connect GOTs to a CC Link IE Controller Network MELSECNET H or MELSECNET 10 PLC to PLC network 1 GOT connection type The following shows connection type of the GOT e CC Link IE Controller Network connection 1 e MELSECNET H connection PLC to PLC network e MELSECNET 10 connection PLC to PLC network GOT1000 series CC Link IE Controller Network connection CC Link IE Controller Network System A System B Control system Standby system Station No 1 Station No 2 Tracking cable Diagram 6 37 GOT Connection Method CC Link IE Controller Network 1 GOT A900 series cannot be used in the CC Link IE Controller Network connection 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 L gt GOT1000 Series Connection Manual Mitsubishi Products 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 switch statio
212. LR switch nzo ange YES not ON W D gt vie RUN STOR Return the RUN STOP switch to the 2 switch set to the RUN position 22 RUN position ao 56 85 YES Ea 1 z D gt wn 41 The operation mode can be confirmed by the BACKUP LED 13 CHAPTER 8 5s 2 The control system CPU module can be identified by the CONTROL LED 3 CHAPTER 8 rz 3 When the RUN LED of the standby system CPU module is flashing in the separate mode set the RUN STOP switch of the standby system CPU module from RUN to STOP to RUN 4 When using the CPU module whose first 5 digits of serial No is 09012 or later refer to Sections 8 1 9 and 8 1 10 for the description of error detected by the standby system after switching 2 systems z F ar ao o e o zZ O O ol w l D 2 O hA 8 1 Troubleshooting Flow 8 10 8 1 4 When the System A System B CPU module RUN LED is not ON 8 TROUBLESHOOTING 8 11 MELSEC TE eries 1 Is the ERR LED ON or YES flashing Has a remote STOP PAUSE been done Perform a remote RUN to set to RUN status YES Is the RUN contact PAUSE contact ON Set to RUN status by turning off the RUN contact PAUSE contact Y Connect GX Developer to the control system CPU module and check for faulty behavior using the System Monitor PLC diagnostics 4 This is a hardware fault in the CPU module so please contact the
213. LSOFT application Operation mode is being changed from backup to separates J Please change RUN LED blink PLC from STOP status to RUN status After it Please execute the change of Operation mode again lt E5 010a4258 gt Lu E wn gt wn i Zz lt x Q a W X o Z O O Z Le Diagram 5 44 Error Dialog Box Displayed on GX Developer REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING 5 4 Operation Mode Change Function 5 62 D REDUNDANT SYSTEM FUNCTIONS Program execution MELSEC TE eries 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 Cc I system Standby system E Continues 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 c
214. LSOFT series GX Developer x MELSOFT series GX Developer Some error has occurred while processing Some error has occurred while processing i Please check the status Please check the status system 4 system 4 Parameter Parameter Program system B Parameter Diagram 5 65 First five digits of serial number for the Diagram 5 66 First five digits of serial number for the Redundant CPU Redundant CPU on system A is 09101 or lower on system A is 09102 or higher and that for the Redundant CPU on system B is 09101 or lower 5 99 5 6 Online Program Change for Redundancy 5 6 1 Writing to the CPU Module in STOP Status D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries 5 6 2 Program Change While CPU is Running Data are written to both systems while CPU is running in the following cases e Online program change e Writing files in RUN e T C set value change Refer to the following manual for details on the 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 Writin
215. M NETWORKS M ELSEG Q series The control system Ethernet 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 the control system CPU module receives the system switching request from that Ethernet module The system switching request can be set to be issued or not in the network parameters as indicated in 3 Communications error occurred System A Control System System B Standby System g a System switching request fal m O System A Control System System B Standby System noon ooo000 mmunication not possible alfunction severed cable EA Diagram 6 21 Operation when a communication error or disconnection is detected 1 Only the QJ71E71 100 can detect disconnection A system switching request is not issued when Ethernet interface module is mounted to the extension base unit 6 27 6 2 Redundant System Network Overview 6 2 3 Ethernet REDUNDANT SYSTEM NETWORKS MELSEC KE eries 1 Overview of Communication with External D
216. M1574 Tracking Block No 55 Tracking Trigger SM1575 SM1576 Tracking Block No Tracking Block No 56 Tracking Trigger 57 Tracking Trigger SM1577 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 87 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 M ELSEG Eseries Set By User or System User D REDUNDANT SYSTEM FUNCTIONS MELSEC KE eries 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 i PID Control Control System Standby System Special Relay SFC Data Internal
217. MING NETWORKS CAUTIONS TROUBLESHOOTING 5 6 Online Program Change for Redundancy 5 104 5 6 2 Program Change While CPU is Running D REDUNDANT SYSTEM FUNCTIONS 5 105 MELSEC TE eries 4 System Switching During Online Program Change Table5 54 shows the operation when the reason for system switching occurs during online program change Table5 54 System Switching During RUN Write Redundancy Compliance Execution Automatic System Switching System Switching Execution System Switching Condition i During RUN Write Stop error O System switching request by network module x 1 System power OFF CPU module hardware malfunction Manual System Switching O CPU module reset O O 1 2 System switching instruction x x System switching request from GX Developer Yes xNo 41 The CAN T SWITCH error code 6220 continuation error occurs in control system CPU module that executed the system switching instruction System switching has failed due to online program change is set in the detailed information special relay 2 The error dialog box in Diagram 5 69 will appear on the GX Developer which requested the system switching E MELSOFT application i T peripheral device or anather peripheral device are operating online change function J Please execute it again after it completed online change Function lt E5 010a424c gt Diagram 5 69 Error Dialog Box Dis
218. NDANT SYSTEM REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS bas z o a g OF o3 E ao TROUBLESHOOTING 7 4 Precautions at System Switching Occurrence T 17 PROGRAMMING CAUTIONS e Input is returned corresponding to output Response input X10 gt d I i i Output Y10 Program example Scan execution type program Prepare tracking transfer data Scan execution type program MO X10 h SET Y10 Error occurrence Prepare tracking MELSEC TE eries I I MO OFF I t I I Wait Wait transfer data Control system i Fa END i pa END i CPU module H l Doo Send i Send Send Tracking transfer 4 Tracking transfer Receive eens Receive PUessing Receive Scan execution i i System type program Standby system i i POEA CPU module i END 0 H c I N v I syst iy i i ew control system Reflect tracking Output Reflect tracking Output Output CPU module transfer data i P transfer data ouge P i i SET Y10 SET Y10 SET Y10 END processing END processing END processing Program ON ON T i ore l I I I X10 OFF I i l Y10 of CPU OFF l or o o EENEN LSE po de module External output of Y10 Tracking setting is set to M X and Y Diagram 7 16 Data Output is Not Reflected to New Control System CPU Module 7 18 7 4 Precautio
219. NET 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 remote master station and system B as the multiplexed remote sub master station 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 Multiplexed Remote Sub master Station Multiplexed Remote Master Station lt lt Send and receive data Receive data from the remote I O station and send receive data with the remote master station Control based on data received with the remote station and receive data with the remote sub master station nM Receive data
220. NS b Ch MELSEC TE eries anging From Separate Mode to Backup Mode Connect GX Developer to the control system CPU module Select Online Redundant operation from the menu bar of GX Developer to open the Redundant operation screen 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 Click on the Execute button Run in separate mode BACKUP ON amber Control system BACKUP Standby system ON amber Test 01 ot Tracking cable Redundant operation Connection target information backup mode Connection interface COM1 Target PLC lt gt PLC module change operation Stationno Host PLC type Q25PRH PLC status System type RUN Control system Operation mode Separate mode GX Developer Change to backup mode Remote operation C System switching C Memory copy Change operation mode ERa z Memory copy progress status Select Backup mode 5 59 Run in backup mode BACKUP
221. Network Module Cannot execute system switching ignores system switching request System Switching Request System Switching Instruction System Switching Request from GX Developer etc Cannot execute system switching instruction cannot be executed due to standby system operation Cannot execute system switching Returns error code 4240H on startup Can t execute on standby system Communication from GX Developer etc Communication specified by control system CPU module Communication error Returns error code 4248H on startup inconsistency 2 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 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 5 3 The System Switching Function 5 3 6 System Switching Precautions 5 56 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu wn gt wn Zz a a Zz a W a o Z O O Z Le REDUNDANT SYSTEM NETWORKS PROG
222. Normal l station Network connection a 8 BHA a 8 BH S al a HE H S al BIE al oO ej amp Tracking cable Extension base l Sao aed all CC Link CC Link connected H UREK Personal Remote Remote device computer I O station station oo ee ee MELSECNET H MELSECNET 10 Mode PLC to PLC network Series Series Series Computer CC Link Ethernet link connected connection connected QCPU QnACPU Normal Normal station station ne GOT1000 Series GOT A900 Series MELSECNET H Remote I O network MELSECNET H PLC to PLC network Serial communication module Remote l Remote Remote I O module I O station I O station a 5 GOT1000 Series GOT1000 Series GOT1000 Series GOT A900 Series GOT A900 Series GOT A900 Series CPU directly Computer link Ethernet connected conne
223. O OFF i OFF l l T l I I t LON i l i l Y10 of CPU module OFF L OFF pem ot 1 J ON O i l l t External output of Y10 OFF l i OFF 1 r 1 j Diagram 7 19 Chattering Occurs to Output by Timer Contact 7 4 Precautions at System Switching Occurrence T 21 SYSTEM REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS z o a g OF o3 E ao TROUBLESHOOTING TRACKING CABLE CONFIGURATION OVERVIEW REDUNDANT SYSTEM PROGRAMMING CAUTIONS T 22 MELSEC TA eries 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 timer is shown in Diagram 7 20 Program example Before measures TO z SET Y10 T10 P RST Y10 After measures M1 E SET Y10 TO PLS M1 q Delays SET Y10 by one 7 scan from PLS M1 M11 E 7 RST Y10 q T10 F PLS M11 q Delays RST Y10 by one 5 scan from PLS M11 Diagram 7 20 Program Example when Outputting by timer contact EJPOINT Set Do tracking at Signal flow memory tracking setting on Tracking settings in redundant parameter 3 Precautions regarding writing data from the GOT and external device etc Pay attention to the followin
224. OHOHHOHOSOHSOHSSSHSOHSHOOHOOOEE 5 36 System switching using GX Developeressssseseeee2 5 38 System switching when a fault occurs in the control system COCCOO OOOO OO OOOO OOO OOOO OOOO OOOO OO OOC OOOO OOO OOOOS 5 35 INDEX 3 T The case where the BACKUP LED of the CPU module is on red cocococoooooooooooooooooooooooo00000000 OF The case where the MODE LED does not turn on The case where the control system CPU module SYSTEM A B LED is flashing eeeseeeseeseeessee 8 8 The case where the System A System B CPU module RUN LED is not on cescecceccccceccccccceccccsccsecces 8 10 Tracking CablE sccscccocoococooooo00000000000000000000000 3 1 Connecting a tracking Cable sesesseseseeseseseeeeses 3 3 Disconnecting a tracking Cablesseseseesesseseseseee 3 4 Minimum bending radius eecccccccccccccccccccccceces 3 7 Part NAMES ecccccccocoocoooo0000000000000000000000000 3 1 SPECIFICATIONS eerceerccccccccccccsccccssoccssoocccoocces 3 1 Tracking data ccccccccccccccccccccccccccccccccccccccvcccee 5h 74 Tracking function cecccccccccccccccccccccccccccccccccceee 5 73 Tracking trigger coooooooooooooooo000000000000000000000000 D OG Transfer tracking data during online program change enable flag ccooooooooooooooo0000000000000000000000000000 D 1 0G TRK CABLE ERR eeseseesessesesoseeseseeseseesess 5 4 5 8 W Waiting time for online program change standby system LALITA 5 106 Wiring to a power supply modulee e eseeeseeeeeeeeesese 4 7 Writ
225. ONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu wn gt wn Zz a a Zz fa W a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG Q series c Memory Copy Precautions 1 Before memory copy the standby system CPU memory will be automatically formatted Then the PRG MEM CLEAR error code 6400 stop error will occur in the standby system CPU module However if a stop error has occurred before memory copy the PRG MEM CLEAR is not detected Memory copy is stopped when any of the following operations is performed during memory copy At this time the memory contents of the standby system CPU module will be illegal Perform any of the following operations after confirming that memory copy is completed e Power off the control system or standby system e Reset the control system or standby system CPU module 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 e Tracking cable fault d How to confirm memory copy completion Completion of memory copy can be confirmed by the special relays and GX Developer 1 Confirmation by special relays When memory copy is completed the special relay Memory copy to other sys
226. OT Connection Type when Mounting to Extension Base Unit W wn gt n j A Ed a Zz fa W a n X x e z E W zZ PROGRAMMING CAUTIONS TROUBLESHOOTING 6 3 Communication between the Both Systems CPU Module and GOTs 6 50 6 3 4 When Connecting GOTs to a Ethernet 6 REDUNDANT SYSTEM NETWORKS 6 51 MELSEC TE eries 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 L gt GOT1000 Series Connection Manual Mitsubishi Products b GOT A900 series The GOT specifies the target communication station connected to Ethernet by the network No and station No It is necessary to specify the station No of systems A and B when communicating with the redundant system in the GOT It is also 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 L gt GOT A900 Series User s Manual GT Works2 Version2 GT Designer2 Version2 compatible Connection System Manual 6 3 Communication between the Both S
227. OUBLESHOOTING 8 35 MELSEC TE eries 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 1 Clear the latest errors and any errors that occurred simultaneously in the error history 1 When error clear operation is performed and the error is cleared the SD0 SD1610 information shows No Errors Therefore the errors that occurred simultaneously with the latest one cannot be confirmed by SDO SD1610 Annunciator F ON error code 9000 Whether Annunciator F is ON error occurrence is detected and the number of annunciato
228. Operation mode change using switches of bus switching module AGRAF 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 SWLJIVD GPPQ N A Applicable GX Developer Version 8 18U and later is applicable SWOD5C GPPW and later is applicable 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 APPENDICES MELSEC KE eries Table App 1 Comparison of Q4ARCPU and QnPRHCPU Redundant Systems Continued Ww Sb Item QnPRHCPU Redundant System Q4ARCPU Redundant System D 5 Instruction Restrictions Instructions shown in Table App 2 are inapplicable Ra uy W Special Relay Some special relays are different 3 x z Special Register Some special registers are different 3 ine N A A compatible Special Must be changed to a special relay applicable for Applicable Relay SM1000 and later 3 Program QnPRHCPU A compatible Special N A it O Registers SD1000 and Must be changed to a special register applicable Applicable fa later for QNPRHCPU g Number of Steps Number of steps fo
229. PU 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 module and execute the instruction Enable manual system switching E 4 System A Calculatin System B Stopping Calculation System A Syst B SM1592 gt Control 3 Standby es er all ys gm System System 1 Process Block 1 3 Alcs R Ar i i p i aye A i a i SP CONTSW K1 M1 g BHA J i S H m m a E E E zl E RUN Control Process Block 2 Execute program system Standby Normal Standby Tracking cable 1 system SP CONTSW K2 M2 The system i Stop program oe swiching i System switching instruction is 1 Process Block 3 executed ke K a END System i SP CONTSW K3 M3 Begin T switthing System A End calculation System B calculating sy 2 Control System Standby System gt Standby System Control System i
230. Q12PHCPU and Q25PHCPU Generic term for the Q12PRHCPU and Q25PRHCPU Generic term for the QOQOUJCPU QOOUCPU Q01UCPU QO2UCPU Q03UDCPU QO4UDHCPU QO6UDHCPU Q10UDHCPU Q13UDHCPU Q20UDHCPU Q26UDHCPU QO3UDECPU QO4UDEHCPU QO6UDEHCPU Q10UDEHCPU Q13UDEHCPU Q20UDEHCPU Q26UDEHCPU Q50UDEHCPU and Q100UDEHCPU Abbreviation for Mitsubishi MELSEC Q Series Programmable Controller D5C GPPW E GPP function software package compatible with Product name for SW the Q series indicates the version Abbreviation for the operation system that includes MELSOFT and EZSocket partner products Abbreviation for the QJ71GP21 SX and QJ71GP21S SX CC Link IE Controller Network module Abbreviation for the MELSECNET H network system Abbreviation for the QU71LP21 QJ71LP21 25 QU71LP21S 25 QU71LP21G QJ71LP21GE and QJ71BR11 MELSECNET H network module Abbreviation for the MELSECNET 10 network system Abbreviation for the Ethernet network system Abbreviation for the QJ71E71 100 QU71E71 B5 and QU71E71 B2 Ethernet interface module A field network system where data processing for control and information can be simultaneously performed at high speed Abbreviation for the CC Link system master local modules Generic term for the Q33B Q35B Q38B and Q312B main base units Generic term for the Q32SB Q33SB Q35SB slim type main base units Another name for the Q38RB redundant power supply base unit Generic term for the Q52B and Q55B
231. QnPRHCPU MITSUBISHI Redundant System oS ATOL PD series Mitsubishi Programmable Controller Q12PRHCPU WELSEB Q iene SAFETY PRECAUTIONS Read these precautions before using this product Before using this product please read this manual and the relevant manuals carefully and pay full attention to safety to handle the product correctly In this manual the safety precautions are classified into two levels N WARNING and N CAUTION WARNING 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 minor or moderate injury or property damage e e all Under some circumstances failure to observe the precautions given under A CAUTION may lead to serious Consequences Observe the precautions of both levels because they are important for personal and system safety Make sure that the end users read this manual and then keep the manual in a safe place for future reference Design Precautions WARNING Configure safety circuits external to the programmable controller to ensure that the entire system operates safely even when a fault occurs in the external power supply or the programmable controller Failure to do so may result in an accident due to an incorrect output or malfunction 1 Configure external safety circuits such as an emergency st
232. RAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS 5 57 MELSEC TA eries 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 If 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 MELSEGC TE
233. RATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS 5 101 MELSEC TA cries 3 Tracking Execution During Online Program Change Use the special relay SM1710 Transfer tracking data during online program change enable flag to enable or disable the tracking execution of the following control data during online program change e Internal device Table5 44 e Special relay Table5 46 Special register Table5 47 e SFC data Section 5 5 3 2 e PID control instruction data Section 5 5 3 2 Make sure to set SM1710 to on or off whether or not to execute tracking before executing online program change If the special relay is turned on during online program change tracking will not be executed 5 6 Online Program Change for Redundancy 5 6 2 Program Change While CPU is Running D REDUNDANT SYSTEM FUNCTIONS a When SM1710 is OFF Default When SM1710 is off tracking will be suspended until online program change is complete aLS eG Q series 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 in
234. RUN Status re o o 56 z2 ao 9 zZ fe E N a a 5 a 5 10 Redundant CPU Functions Restricted in Redundant System 5 136 5 10 2 Remote Operation for Redundant System D REDUNDANT SYSTEM FUNCTIONS 2 MELSEC falser When watchdog timer error has occurred in the standby system CPU module When a watchdog timer error has occurred in the standby system CPU module only the control system CPU module is reset and the standby system CPU module is not reset When performing remote reset for the standby system CPU module in which a watchdog timer error has occurred set the communication route where the tracking cable is not relayed Control STOP Standby Watchdog timer error system system g a ooo oo0000 ooo000 jo ojele A 7 Oooo eo l NC ols Oolec eo lola Tracking cable GX Developer Control STOP Reset gt STOP Standby Watchdog timer error Remote operation Connection interface Target PLC PLC status System type Operation Connection target information system COMI lt gt PLC module STOP PLC Reset z Extract m
235. 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 Diagram App 33 Program Example Appendix 6 Precautions for Using Serial Communication Module Appendix 6 8 PRR Instruction Appendix 6 Precautions for Using Serial Communication Module App 52 APPENDICES MELSEC KE eries 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 PROCESSING TIME FOR REDUNDANT SYSTEMS 1 Device of programmable controller 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 APPENDICES 2 W O signal Table App 43 List of I O Signal V O signal Signal name Description CH1 side CH2 side Transmission normal Xn0 Xn7 ON Normal completion completion x EET g Transmission abnormal i z 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 ON Module error occurred Watchdog timer error X n 1 F OFF Module being normally WDT error operated Yn0 Yn7 Transmission request ON Requesting transmission
236. SMYOMLAN WALSAS LNYANNAAY WALSAS LNYANNAAY SNOILNVO O NINWYH9O d ONILOOHSSTENOdL oe 5 6 5 4 Operation Mode Change Function REDUNDANT SYSTEM FUNCTIONS MELSEC TA eries 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 the program During Stop Does not execute Reflects the operation result of Signal Flow Memory theconirol 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 files in RUN Executable Input from Input Module on Main i Base Unit Inputs it Output to Output Module on Main Outputs it Base Unit Output from input module on A 4 j Inputs it extension base unit 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 Automatic 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
237. Standard ROM Based on the PLC parameter settings Intelligent Module Parameter Initial Settings The intelligent module parameters are reflected 1 Clear device data by latch clear 5 31 5 1 Basic Concept of Redundant System 5 1 6 Start Mode D REDUNDANT SYSTEM FUNCTIONS M IES 26 fel ceries 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 K gt QCPU User s Manual Function Explanation Program Fundamentals OVERVIEW Table5 21 Function List Item Description Reference System Switching Function This function switches the control system and the standby system It changes CONFIGURATION SYSTEM Switching between the the control system to the standby system and the standby system to the SecionE3 ection 5 Control System and Standby control system System There are 2 types automatic system switching and manual system switching k This function switches the operation mode between the separate mode and Operation Mode Change Section 5 4 backup mode This function transfers the operation control data to the standby system to TRACKING CABLE 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 T
238. Startup SPD Pulse Density Measurement Table App 8 Instructions Restricted for PRHCPU Instruction Symbol COM Selection Refresh l For restrictions on COM and ZCOM refer to Section 7 1 7 ZCOM Refresh of Specified Module f Instruction Name Remark Appendix 3 Comparison of QnPHCPU and QnPRHCPU App 12 APPENDICES MELSEC TE eries Appendix 4 Sample Programs when Using CC Link This section explains sample programs that allow the CC Link control to be continued when 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 Diagram App 1 from X Y40 to X Y5F are assigned to the I O number of CC Link master module 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 Syste
239. Station i i eoii ia Station i gt i Output Data Input data Input data Output Data Input data Input data Remote I O station MELSECNET H Remote I O network MELSECNET H Remote I O network Remote I O station Diagram 5 45 Operations When Changing from Backup Mode to Separate Mode b Operations When Changing from Separate Mode to Backup Mode Separate mode Back up mode Calculating Standby Calculating Standby Operation stop Switch to backup mode i i i F Multiplexed Input data Multiplexed Input data pees i Multiplexed Reno QNPRHCPU Remote Master QnPRHCPU Sub master QnPRHCPU Remota Master QnPRHCPU Sub master 7 r Output Data Station Output Data Station t Output Data Station Station i A mccc i i i Output Data Input data Input data Input data Input data MELSECNET H MELSECNET H 5 67 5 4 Operation Mode Change Function Remote O station Remote I O network Remote I O network Remote O station Diagram 5 46 Operations When Changing from Separate Mode to Backup Mode MELSEC TE eries D REDUNDANT SYSTEM FUNCTIONS Memo MAIAY3A0 NOLLVYNSISNOO gaY ONIMOVeL WALSAS LNVONNGSY WALSAS Y dN ONILYVLS Od J4NAIDOYd LO SNOILONN 4
240. System D REDUNDANT SYSTEM FUNCTIONS 5 1 3 Operation Mode ELSEG seres The operation mode determines the redundant system operation methods Following three operation modes are available Backup Mode e Separate Mode e Debug mode Use GX Developer to switch between the backup mode and separate mode Refer to Section 5 3 for switching between the backup mode and separate mode Switch the operation mode to the debug mode in the redundant parameter settings 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 control and continues the system operation To enable the standby system to continue the system operation when the control system goes down the data of the control system must be continuously transferred to the standby system through the tracking cable Refer to Section 5 5 for details on the tracking function System B Stopping Calculation Standby ooo ooo000 SystemA Calculating Control System z s Hia elle B 8 H Boao Tracking cable System A Control J End calculation System B Standby Begin
241. System B connecter System A connecter 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 5 3 5 1 Basic Concept of Redundant System 5 1 1 Determination of System A System B D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries 2 Confirming system A System B 1 Identify system A and system B by checking the SYSTEM A and SYSTEM B LEDs of CPU modules OVERVIEW Table5 1 Identify system A and system B by checking the SYSTEM A and SYSTEM B LEDs CPU Module LED LED Statuses Q12PRHCPU move J Backup C LED Name System A System B RUN CONTROL ERR SYSTEMA SYSTEMA OFF USER SYSTEM B a SYSTEM CONFIGURATION SYSTEM Refer to the following manual for details on the CPU module LED L gt QCPU User s Manual Hardware Design Maintenance and Inspection 1 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 TRACKING CABLE Table5 2 Confirming SM1511 and SM1512 to Identify System A and System B System A ON OFF System B OFF ON PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM 3 Precautions When using the redundant system in the backup mode conne
242. U User s Manual Function Explanation Program Fundamentals QCPU User s Manual Multiple CPU System eS _ Outline MELSEC TA eries O Redundant system QnPRHCPU User s Manual Redundant System Confirmation of connection methods for power supply module base unit and I O module Construction of redundant system confirmation of start up procedure and I O number assignment Details Confirmation of the configuration and memory of sequence programs aaa Details Confirmation of the functions parameters devices etc of the CPU module Confirmation of the troubleshooting Details Confirmation of the error codes Details OVERVIEW MELSEC KE eries Table1 2 List of programming manuals of redundant CPU OVERVIEW PID control Process Structured 5 control Instructions Instruction Text r QCPU Q mode QCPU Qmode QnPHCPU QnACPU QnACPU QnPRHCPU QCPU Q mode QCPU Q mode Programming Programming Programming QnACPU Programming Manual Manual PID Manual Process Programming Manual QCPU Q mode Programming Manual Structured Text Edition Purpose Common Control Control LV ETATOE1 09 MELSAP L Instruction Instruction Instruction CONFIGURATION SYSTEM Confirmation of usage of sequence instructions basic instructions application instructions etc g
243. W 41 Use version 1 16S or later when mounting CC Link master module on extension base unit A ZO ae rad g o 56 3 z 5 Q if a O Z 2 3 Applicable Devices and Software 2 17 2 SYSTEM CONFIGURATION MELSEC IA ries 2 4 System Configuration Cautions 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 Redundant CPUs whose first 5 digits of serial No are 09012 or later for both systems e Connnect a redundant type extension base unit as the first extension stage As the second and later stages redundant power extension base units only can be used e Only one redundant type extension base unit can be used per system e Connect IN connector IN1 and IN2 of the redundant type extension base unit to OUT connector of the main base unit e Connect OUT connector of the redundant type extension base unit to IN connector of the redundant power extension base unit e Use the same main base unit models in systems A and B e Configuration of multiple CPU system is not allowed Do not power OFF or reset the control system in Separate mode Do not perform boot operation of a Redundant CPU whose first 5 digits of serial No is 09011
244. WITCH can be cancelled by turning ON the error cancel command M100 after checking that the standby system CPU module CC Link IE Controller Network module or 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 K3 sb1588 lt gt ko D1589 KO sD1600 KO gt H when the system cannot be switched normally SD1589 0 system error information SD1600 KO ko sp1590 H KO sD1690 MOVP K6220 SD50 gt and system switching request module No from the host system or other system network module CSM50 gt SD1590 and SD1690 are all normal in the system switching request by the network module SD1588 3 Diagram 8 17 Sample Program to Cancel an Error CAN T SWITCH When executing the error cancel command automatically change error cancel command M100 in Diagram 8 17 to be always ON SM400 Programming of CC Link IE Controller Network or MELSECNET H CC Link IE Controller Network or MELSECNET H network detects a temporary communication error depending on conditions such as power supply ON OFF or cable and noise Create the program using CC Link IE Controller Network or 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 CC Lin
245. When connecting the extension base unit use the Redundant CPU whose first 5 digits of serial No is 09012 or later 7 56 c ao ai z o O 35 if a O aa 2 1 System Configuration 2 3 2 SYSTEM CONFIGURATION MELSEC TE eries 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 2 2 2 2 l slalZie 2 i li fe O i Jaje O i J j jeju E Toft reil oia jlele ai Df JNJ lotr gt I INJrltolyrn ere I amp QINI e Ss I amp sale l 2 ao O 2 e0 SG a a O z o W 2 S x le 2 c J CO 5 5 Co 5 51 8 J3 e ej iS 5 5 oO oO 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 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 to the Q Corresponding Ethernet Interface Module User s Manual Basic for details 2 4 2 1 System Configuration 2 SYSTEM
246. a 5 6 Online Program Change for Redundancy 5 108 5 6 2 Program Change While CPU is Running D REDUNDANT SYSTEM FUNCTIONS 5 109 g h i MELSEC TA eries 3 Changing programs being accessed by the other GX Developer online The error dialog box in Diagram 5 75 will appear if online program change is executed to the CPU module during system switching or operation mode change Mi MELSOFT application Communication trouble or system switching was generated J while executing Online Function to the control system PLC lt E5 010a4253 gt Diagram 5 75 Error Dialog Box Displayed on GX Developer 4 Online program change to CPU module during system switching or operation mode change The error dialog box in Diagram 5 76 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 lt ES 010a4 1cS gt Diagram 5 76 Error Dialog Box Displayed on GX Developer Online program change in Separate Mode 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 Extension of scan time due to online program change If online program change is execute
247. a bit 7 8 Parity bit Not set Set Odd even parity Odd Stop bit 1 2 Sum check code _ Notset Set Write during RUN Prohibited Setting change __ Prohibited Communication speed 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 Unit bps Unit bps 50 OFy 14400 064 300 004 19200 074 600 Olp 28800 084 1200 02 38400 094 2400 03H 57600 OAH 4800 044 115200 OBy 9600 054 230400 OCH 230400bps is applicable for the CH1 side of the QJ71C24N R2 R4 only 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 QJ71C24N 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 App 39 Appendix 6 Precautions for Using Serial Communication Module Appendix 6 2 UINI
248. acking Trigger for Tracking Block No 1 It is possible to make the settings at the tracking settings in the redundant 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 Table5 49 Tracking Triggers Description Default When setting batch of internal devices at the tracking Turns on at the time of power ON reset STOP to RUN Set By User or System OFF Disable When the detailed device settings are made at the SM1520 Tracking Block No 1 Tracking Trigger Tracking tracking settings systemy ON Enable User Tracking e The trigger turns on at the time of power ON reset STOP to RUN if tracking block No 1 is set to be tracked in the automatic tracking parameter e Turn off if tracking block No 1 is set to not to be tracked in the automatic tracking parameter SM1521 Tracking Block No 2 Tracking Trigger SM1522 Tracking Block No 3 Tracking Trigger SM1523 Tracking Block No 4 Tracking Trigger SM1524 Tracking Block No 5 Tracking Trigger SM1525 Tracking Block No 6 Tracking Trigger SM1526 Tracking Block No 7 Tracking Trigger M1527 Tracking Block No 8 Tracking Trigger SM1528 Tracking Block No 9
249. ag i z Normal Standby j Standby H g E RUN system Control RUN g g z Stop program system Execute program ee A z 1 l Tracking cable J L y J Diagram 5 28 System Switching Operation by System Switching Instruction 1 Refer to the following manual for details on the system switching instruction L gt MELSEC Q L Programming Manual Common Instruction 5 39 5 3 The System Switching Function 5 3 1 System Switching Method D REDUNDANT SYSTEM FUNCTIONS M aL 26 fel ceries 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 switching status flag SM1518 as illustrated in Diagram 5 29 and modify the program so that the instruction will not be executed in the new control system CPU module again OVERVIEW CONFIGURATION SYSTEM Standby system to control system switching status flag SM1518 tt K _ sET wo H system switching command M1000 MO T l HE SP CONTSW K1 M10 1 TRACKING CABLE Cancel Signal 1 When the SP CONTSW instruction M1001 cannot perform a system s
250. al power supply OFF setting for extension in future As the module verify error is preset to stop when the error occurs a stop error is detected in the control system resulting in system switching However since the new control system also detects the module verify error and stops its operation the redundant system stops the control When the module verify error is set to continue even if the error occurs the system switching does not occur and the operation continues with I O numbers used before the error occurrence 5 27 5 1 Basic Concept of Redundant System 5 1 5 Self Diagnostics Function D REDUNDANT SYSTEM FUNCTIONS MELSEC KAri 4 Self Diagnostic at Startup of Redundant CPU The redundant CPU diagnoses the system based on the points described in Table5 19 when the redundant system is powered on or the CPU modules are unreset RESET L CLR switch is set to the neutral position When detecting an error the redundant CPU 3 develops a stop error Table5 19 Self Diagnostic at CPU Module Startup Priority 1 Di g aE Detected Error E 1 CPU module hardware check MAIN CPU DOWN 2 1000 to 1009 58 2 Redundant CPU RAM check RAM ERROR 1101 to 1109 3 Hardware Check Operation circuit check OPE CIRCUIT ERR 1200 to 1202 4 Tracking cable connection check TRK CABLE ERR 6120 i 5 Tracking commun
251. am System Configuratione eeseseseeseeeeseceesececceseecesecsceseseoseseesese App 13 Sample Program Names seeseeeeeseeeesocceccccececoceccccecoesccocccoecesscceccsseeesssee ADD 13 Devices Used in Programs eeeeesseeeeeeeeeooceseeeocoeooocecceoeoeoceceeoeseosseeeceeeooes ADD 14 Parameter Settings eeeeeeeeseeeeeeeeeceooeeeeocceooscecceceosocecceceooososeeeceosooseeeeeee ADD 16 Sample ProgramM seeeeeeeesseeeeeececoococecoeceococccccoeooocecceoeoooscceecesoosseeeeeseosee ADD 20 Method for Starting up the Previous Control System cersescescsscscccccsccsccccsscsccscosoosee ADP 26 Precautions for Using Serial Communication Module eessseeeessseeeesssececsoooceocesoooo000 ADD 32 CSET Instruction eeeeeesseeseeeseeecsecoceoosecoceosccocseecseoosseoocosssocscesoseossesoseosee ADD 33 UINI Instruction eeeeeeeeeseecseecosocscecoceoccocosecoceossecoceosseooscesosossseoscossseeseeso ADD 38 INPUT INStruUCtiOn eeeeeeseeeeseecscecceocscecocoocsococeoosocoseooceossecoseeoseooseesseosseeo ADL 41 PUTE Instruction eeeeesseesseesosoessecoceoccocoseooceocceeoseooseooseesocossseoseosseoeseeso ADD 42 GETE Instruction eeeeeseeeseeeeseecsceoccoesceooceoccocoseoosocoseeoseosseooseosseesseesosossee ADD 44 ONDEMAND Instruction e eeseesseeseeeessecsceocsoccseooceocseeoceosseooseesseosssesseossee ADD 46 OUTPUT Instruction eeeeeeeeeeseeceecsseoeseecseocccoooceoscooscecoceossococesssossseesseossee ADD 48 PRR Instruction Co tee AN 50
252. ame No 0 Normal completion 25714 599 26714 615 Data transmission result 1 or more Abnormal completion error code 4004 1024 800 2048 T ansmission 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 50 Appendix 6 8 PRR Instruction APPENDICES MELSEC TE eries The program example of sending data by the user registration frame of the nonprocedural protocol communication is shown in Diagram App 33 For the I O signal is X Y80 to X Y9F X50 o i a Aa M50 M50 X9E X9F X80 X81 Y80 3 H Fa Mov K4 DO MOV H1234 D1 MOV H56AB D2 MOV HO D10 MOV H1 D11 MOV H5 D12 MOV H3F2 D13 MOV H3F3 D14 MOV H8001 D15 MOV H8000 D16 MOV H41B D17 MOV HO D18 TO H8 H0B7 D10 kg TO _ H8 H400 DO K3 SET Y80 x80 42 RST Y80 x81 44 FROMP H8 H257 D20 K1 RST 80 App 51 Sets the send data and the number of send data Sets the data to be written to the schedule specification area of the buffer memory Writes each data of CR LF output specification to output frame No specification to the schedule specification area Sets the number of send data Turns ON the send request signal Turns OFF the send request signal if the send completion signal is turned ON
253. 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 EIPOINT 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 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 12 7 2 Cautions on Fixed Scan Clocks and Fixed Scan Execution Type Programs PROGRAMMING CAUTIONS MELSEC TE eries 6 Interrupt during Tracking Processing If interrupt is enabled El status during END processing when an interrupt is issued during tracking processing the CPU will stop the tracking processing and execute the interrupt program Therefore both data of before and after interrupt program execution might be tracked OVERVIEW Example The operations for interrupted 131 execution via an internal timer are shown in Diagram 7 10 CONFIGURATION SYSTEM 10ms content J
254. and enable system switching Step 17 to 38 Refresh the CC Link Step 39 to 55 Perform system switching when system B starts up as the control system Step 56 to 69 Diagram App 10 Sample program overview flow App 23 Appendix 4 Sample Programs when Using CC Link Appendix 4 5 Sample Program APPENDICES MELSEC TE eries 2 Sample Program PROCESSING TIME FOR REDUNDANT SM402 2 0 FMOV HOFFFF D100 K8 gt SM1518 2 MOV H200 D102 i bi Adds 141 to the allowable interrupt defaults l0 to 131 148 to 1255 9 IMASK D100 M f8 11 El fal Zz W SM1518 paa a 12 RST SB40C Set CC Link forced master switching flag to OFF lt RST M100 Set control program execution flag to OFF SET M101 Set system switching execution flag to ON isi iio Set System B first startup system switching flag to OFF M100 U4 x 17 BMOV K4Y1000 6352 K10 Performs a refresh of RY Y1000 to Y109F a Z U4 BMOV 6224 K4x1000 K10 Performs a refresh of RX X1000 to X109F U4 BMOV W1100 6480 K20 Performs a refresh of RWw W1100 to W1113 U4 6736 W1000 K20 Performs a refresh of RWr W1000 to W1013 SE SM1592 Allows system switching by SP CONTSW SB45A SB45B 39 KJ POTS E SB401 Set refresh update request signal to ON B442 SB443 i i m RS SB401 Set refresh update request signal to OFF KO SW443 _ ______________Js M100 Set control program execute flag to ON When System B has started first a
255. andby 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 TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A SM1510 SM1513 SM1515 SM1516 SM1600 o 1 F When M0 is set to ON in the System B 4 i i i ue A m1000 J CPU module Y100 is also set to ON NO M1000 REDUNDANT SYSTEM FUNCTIONS M100 M102 SM1610 When a connection error occurs in the t SET M102 standby system set M102 to ON SM1649 i 11 RST__smM1649 Set SM1649 to OFF RST _ sD1649 Initialize clear SD1649 RST M102 Set M102 to OFF REDUNDANT SYSTEM NETWORKS The error code for standby system J errors is stored in SD1649 16 MOVP SD1610 sD1649 q Set the standby system error clear command SM1649 to ON SET sM1649 20 MCR NO PROGRAMMING CAUTIONS Diagram 8 18 Sample Program for Clearing Standby System CPU Module Error o e o zZ O O ol w l D 2 O hA 8 2 Error Clear 8 34 8 TR
256. ansmission data Data to be sent to an external 1025 to 1535 2049 to 2559 designation device Appendix 6 Precautions for Using Serial Communication Module App 48 Appendix 6 7 OUTPUT Instruction APPENDICES MELSEC LAY ceries The program example of sending data by the nonprocedural protocol communication is shown in Diagram App 32 For the I O signal is X Y80 to X Y9F o km 4444 4 MOV abcdefg D11 J Sets send data and number of send data MOVP HOAOD D15 MOVP K5 D10 TOP H8 H400 D10 K6 7 Writes the number of send data and send data to buffer memory Fser ygo 7 Tums ON send request signal Y80 3 after writing data X80 23 RST Y80 Turns OFF send request signal Zol Reads send error code 25 FROMP He M257 D20 KA Take corrective action to the error according to error code stored in D20 RST Y80 Turns OFF send request signal X60 32 Y8E Turns LED OFF and clears error code Diagram App 32 Program Example App 49 Appendix 6 Precautions for Using Serial Communication Module Appendix 6 7 OUTPUT Instruction APPENDICES MELSEC KE eries 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 PROCESSING TIME FOR REDUNDANT SYSTEMS 1 Device of programmable con
257. apter provides the tracking cable specifications 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 Piz Table3 1 Tracking Cable Specifications 58 3 QC10TR QC30TR Cable Length 1 0 m 3 29 feet 3 0 m 9 87 feet 4 Purpose Connecting the CPU modules of a redundant system 3 Mass 0 15 kg 0 28 kg z Tightening Torque 29 4Necm 3 3 2 Part Names Tracking cable part names are indicated here PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM ase ba li i System B Confirmation Mark Connector Fixing Screw REDUNDANT SYSTEM FUNCTIONS YLOLOO QC10TR REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 3 1 Specifications 3 1 3 TRACKING CABLE M ELSEG Q series 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 malfunction may occur due characteristic deterioration wire breakage etc
258. arting scan execution type program and system switching Diagram 7 9 Operations of Interrupts by Internal Timers at System Switching REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS bas z o a g OF o3 E ao TROUBLESHOOTING 7 2 Cautions on Fixed Scan Clocks and Fixed Scan Execution Type Programs T 11 PROGRAMMING CAUTIONS MELSEC TA eries 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 following 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
259. ate the MELSAP L type SFC program Sold separately QnPHCPU QnPRHCPU Programming Manual Process Control Instructions This manual describes the programming procedures device names and other items necessary to implement PID control using process control instructions Sold separately MELSEC Q L Programming Manual Structured Text This manual describes the structured text language programming methods Sold separately CC Link IE Controller Network Reference Manual Explains the specifications procedures and settings before system operation parameter setting programming and troubleshooting of a CC Link IE Controller Network 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 MELSECNET H network system Remote I O network Sold separately Type MELSECNET 10 Network system PLC to PLC network Reference Manual This manual describes the system configuration performance specifications and programming of MELSECNET 10 network system PLC to PLC network Sold separately Manual Number Model Code SH 080483ENG 13JR73 SH 080808ENG 13JZ28 SH 080809ENG 13JW10 SH 080040 13JF59 SH 080041 13JF60 SH 080076 13JF61 SH 080316E 13JF67 SH 080366 13JF68 SH 080668ENG 13JV16 SH 080124 13JF96 IB 66440 13JE33 Related Manuals Manual Name Q Correspo
260. ations especially program modification forced output and operation status change for the running CPU module from the peripheral connected read relevant manuals carefully and ensure the safety Improper operation may damage machines or cause accidents Do not disassemble or modify the modules Doing so may cause failure malfunction injury or a fire Use any radio communication device such as a cellular phone or PHS Personal Handy phone System more than 25cm 9 85 inches away in all directions from the programmable controller Failure to do so may cause malfunction Shut off the external power supply for the system in all phases before mounting or removing the module Failure to do so may cause the module to fail or malfunction A module can be replaced online while power is on on any MELSECNET H remote I O station or in the system where Redundant CPUs are used Note that there are restrictions on the modules that can be replaced online and each module has its predetermined replacement procedure For details refer to Section 2 4 After the first use of the product do not mount remove the module to from the base unit and the terminal block to from the module more than 50 times IEC 61131 2 compliant respectively Exceeding the limit of 50 times may cause malfunction Do not drop or apply shock to the battery to be installed in the module Doing so may damage the battery causing the battery fluid to leak inside the batt
261. base unit or extension base unit PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 2 4 System Configuration Cautions 2 19 2 SYSTEM CONFIGURATION MELSEC TA eries 3 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 4 Table2 4 Number of modules loaded Applicable Module CC Link IE Controller Network module 2 Type e QJ71GP21 SX e QJ71GP21S SX Limitation on the number of mountable modules per system Up to 2 MELSECNET H module 2 e QJ71LP21 25 e QJ71LP21S 25 e QJ71LP21G e QJ71LP21GE Up to 4 in total of PLC to PLC network and remote I O network 1 Up to 4 in total modules e QJ71BR11 e QJ71E71 B2 Ethernet module e QJ71E71 B5 Up to 4 e QJ71E71 100 CC Link master module e QJ61BT11N Up to 8 1 The number of mountable modules per system indicates the number of modules that can be mounted on main base unit or extension base unit Or it indicates the number of modules that can be mounted on either one of the systems when they are mounted on main base unit 2 CC Link IE Controller Network module or MELSECNET H module cannot be mounted to the extension base unit 3 Possible only when the first five digits of serial number for the Redundan
262. 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 REDUNDANT SYSTEM NETWORKS 5 Memory Card Setting Status Consistency Check The memory card setting status consistency check cannot be performed during online program change PROGRAMMING CAUTIONS TROUBLESHOOTING 5 6 Online Program Change for Redundancy 5 110 5 6 2 Program Change While CPU is Running D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q 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 Failed CPU module Control system E T oo00 oooooo 4
263. ble JA 0 HL ISET F10 H a uses ean se abs cay E C A A A O 1 Annunciator tracking System switching System A Control system System B Control system Standby system Standby system LED status a e a lanes LED status USER m T H F z USER EJ Program g E Program a MO 0 SET F10 T 14 H Tracking cable MO 0 HASET F10 Diagram 7 12 Operation of USER LED When Annunciator F10 Turns On 7 3 Precautions for Using Annunciator F in Redundant System PROGRAMMING CAUTIONS MELSEC KE eries 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 SM1518 0 D lt gt K8FO KO SET F2047 Y When K8FO 7 0 F2047 provided to turn on the USER LED is turned on 8 RST F2047 H When M100 turns on F2047 is turned off DMOVP KO K8F0 H When M100 turns on FO
264. cccoccccocce 5 4 5 8 G200 eccccccccccccccccccccccccccccccccccccccccccccocosees 5 34 G210 ecsscccoocoo0o000000000000000000000000000000000000 5 34 Error details window eeeeeeeeeeso00000000000000000000 5 34 Error detection processing ccoocooooooooooo000000000000 D_2G Extended scan time eecececcccccccccccccccccccccccccccece OD F Featu ES cocccccccccccccccccccccccccccccccccccccoecoecooolee 1 6 File consistency CHECK eeccccccccccccccccccccccccccccccs 5 18 Function List OO a 5 32 H Hot start mode COCCOOOOOOOO CEO OOOOO OOOO OOO OOOO OOOOOOOOEEE 5 30 I Initial start mode SOHOSOHSOHSHSSHSHSSH 000000000000000 00000 5 29 Internal devices COCOCOOCOCOOCOOCOCOOCOOCOOCOOOOOOOO000000000000000O 5 77 Interrupt from network module eeessseeeeesseeeee000 7 12 L LED BACKUP eeceecccccccccccccccccccecccccsseseees 5 10 5 11 CONTROL e seseeseesesecesecsocsosecesecsocsossesseos 5 7 List of Q Siries CPU modules eeeeeeseeeesececeesecee 1 2 M Manual system switching ocoooooooooooo000000000000000 5 39 System switching by the system switching instruction 0000000000000000 00000000000000000000000000000 5 39 System switching using GX Developer s sse 99995 38 Memory card setting status consistency checks 5 23 Memory copy from control system to standby system Memory copy from control system to standby system using GX Developereeeeeccocccecccccccccccoccccoccccs 5 114 Memory copy function ecccccccccccccccccccccccccccces 5
265. ce The project PLC and the connected PLC are different lt E5 0180840b gt Diagram 5 41 Error Dialog Box Displayed on GX Developer 5 4 Operation Mode Change Function D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries e During online program change If the error dialog box Diagram 5 42 appears on GX Developer wait for RUN write to complete and then change the operation mode OVERVIEW E MELSOFT application D 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 42 Error Dialog Box Displayed on GX Developer During memory copy from control system to standby system If the error dialog box Diagram 5 43 appears on GX Developer wait for memory copy from the control system to the standby system to complete and then change the operation mode CONFIGURATION SYSTEM E MELSOFT application e The memory copy function is being executed DD Please execute it again for a while after time TRACKING CABLE lt E5 010a4247 gt Diagram 5 43 Error Dialog Box Displayed on GX Developer When a stop error occurs in the control system CPU module the RUN LED flashing If the error dialog box Diagram 5 44 appears on GX Developer cancel the control system CPU error and change the operation mode REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol E ME
266. ceive Receive E Incomplete Standby system j 5 CPU module 0 Run program g m Adjust Tracking Adjust Tracking data 1 data 2 Device data for new control system CPU module Diagram 5 55 Tracking Operation Timing When Program Execution Time gt Tracking Processing Time New Control system CPU module 2 Tracking when program run time lt tracking time Scan time Prepare Tracking Prepare Tracking Prepare Tracking data 1 data 2 data 3 Run program 1 END 0 END O END 0 END O END 0 Control system __ m CPU module Run Run Run Run p program 2 program Sprogram program Send _ Send ___ eee J Tracking i Tracking processing 1 processing 2 Receive Receive Standby system m ms CPU module i x Adjust Tracking Adjust Tracking data 1 data 2 Diagram 5 56 Tracking Operation Timing When Program Execution Time lt Tracking Processing Time 5 93 5 5 Tracking Function 5 5 7 Tracking Mode D REDUNDANT SYSTEM FUNCTIONS Control system CPU module 2 Run program 1 END Ja b Tracking in Separate Mode Scan time Prepare Tracking data 1 Run program 2 New Standby system CPU module Standby system CPU module p Send m 4 Tracking Receive ELS eG Q series Prepare Tracking processing 1 e END 0 END data 3 Prepare Tracking ata 3
267. ching cooooooooooooooo000000000000000000000 553 System switching enable disable flag from network MOU eccceccccccccccccccccccccccccccccccccccecccccoses HH 3 Special relays for Memory Copy ssesseseeseeeeesees 5 112 Special relays for system switching sseresseseseeeeee 5 53 STANDBY eececccccccccccccccccccccccccccccccccccecseesees 5 34 Standby system 00oooooooooooooooo000000000000000000 1 22 5 5 Start mode eccccccccccccccccccccccccccccccccccccccvcvcscse 5 DO Hot start mode ecccceccccccccccccccccccccccccccccccces 53 Initial start mode eececcccccccccccccccccccccccccccccees 5 29 Starting up GX Developereeeseeececcccccccccccccssoeee 4 13 Synchronized tracking mode ssseeseeeeeeeseeseeseesee 5 91 System A cocccccccccccccccccccccccccccccccccccoccccce 1 22 5 3 System A discriminating flag SM1511 sessessessess 5 4 System B coccccccccccccccccccccccccccccccccccccccccce 1 22 5 3 System B discriminating flag SM1512 sessessessees 5 4 System configuration Ceccccccccccccccccccccccccccccccocs 21 Communication via CC Link ssesseeseseescesceseeees 2 9 Communication via MELSECNET H PLC to PLC network COCOOO OOOO OO OOO OOOOH OOOO OOO OOOOH OOOO OOO OOOOOOOOCE 2 5 Communication via MELSECNET H Remote O network eeccccccccccccccccccccccccccccccccccccccosccccces D_ Communication with a Host OPS PC etc eeesss 2 4 Redundant System Peccccccccccccccccccccccccccccccocs DD System configuration cautions sesserseseeseescesecees 2 18 Modules that can be mou
268. ck And Tracking Trigger D REDUNDANT SYSTEM FUNCTIONS 5 85 MELSEC TA eries 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 Z0 to Z15 Diagram 5 51 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 Number 2 Tracking Trigger a Tracking Trigger Overview MELSEC KE eries A tracking block trigger is a special relay that determines whether to track the multiple blocks of internal device data Tracking block triggers are assigned to each tracking block K gt Table5 49 When executing tracking turn on the tracking trigger that corresponds to each tracking No to execute tracking in the program b Setting Tr
269. cking starts S Y If tracking time is longer than program execution time the next tracking cannot 3 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 A based on the tracking data of up to 2 scans before g HS 1 tracking when program run time 2 tracking time E 5 cas Scantime _ Prepare Tracking data 3 Prepare Tracking Prepare Tracking ata 3 data 1 data 2 h a Control system Run ve Run Te Run e END END END CPU module program 1 0 program 2 9 program 3 z J New Standby system Non executed CPU module Send H Send H Send 4 Tracking 4 Tracking 4 Tracking processing 1 processing 2 processing 3 3 u Receive c Receive _ Receive Incomplete Cay use Standby system 5 5 29 Z CPU module 0 Run program ORS ll m _ QE iT an New Control system CPU module Adjust Tracking data 1 Adjust Tracking data 2 Device data for new control system CPU module Diagram 5 53 Tracking Operation Timing When Program Execution Time gt Tracking Processing Time ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le 2 Tracking when program run time lt tracking time Scan time fi wn Prepare Tracking Prepare Tracking Prepare Tracking D data 1 da
270. 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 16 For details of CC Link IE Controller Network or MELSECNET H refer to the following manual CC Link IE Controller Network Reference Manual 3 Q Corresponding MELSECNET H Network System Reference Manual PLC to PLC network c Usage in debug mode when CC Link IE Controller Network modules are mounted When CC Link IE Controller Network modules are mounted do not connect CC Link IE Controller Network module on both systmes to the network at the same time In the debug mode the system B CPU module uses the same parameters for the system A CPU module for operation Therefore control station overlap and station number overlap occur when connecting to the network at the same time 6 2 Redundant System Network Overview 6 16 6 2 1 CC Link IE Controller Network or MELSECNET H PLC to PLC network OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM REDUNDANT SYSTEM FUNCTIONS ez W wn gt n j rA Ed a Zz fa W a n X x ie z E W zZ PROGRAMMING CAUTIONS TROUBLESHOOTING 6 6 17 REDUNDANT SYSTEM NETWORKS MELSEG Fl caries 6 2 2 MELSEC
271. creases 16K word a 3 Device detail settings a Tracking block No Bi z Device range settings Z O 4 7 Device total Maximum 100 K K word File register file settings g z Tagetmenay Fie rame eae ees ey SoZ aza BES 5 oe gal X Ey Tracking characteristics setting anr Synchronized tracking mode T ake more scan time Program priority mode 5 Default rT pu wn Diagram 5 49 Tracking Setting Screen 5a 36 Ze a Table5 48 Tracking Setting Items and Ranges WS Item Range Default Reference e Internal device block setting Section Tracking device setting Internal device block setting Device detail settings 5 5 3 a A No tracking Section gt Signal flow memory tracking setting 7 No tracking E e Enable tracking of signal flow memory 5 5 3 Zo Section S5 Tracking block No e 1 to 64 1 ae 5 5 5 ST ez Device 4 Table5 44 Default Tracking Section Device range Settings Points Start Table5 44 Tracking Range Set by User Range 5 5 3 Start End gt e Synchronized tracking mode Section Tracking characteristics setting N Synchronized tracking mode 9 Program priority mode 5 5 7 e Do auto forward Tracking block No 1 Do auto forward Tracking Section 22 Do auto forward Tracking block No 1 j fe e Do not auto forward Tracking block No 1 block No 1 5 5 5 SE Target Memory card SRAM ES memory Standard RAM File register Sets tracking file register file name fil
272. ct 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 E POINT When starting up a single basic system use the debug mode Refer to Section 5 1 3 for the debug mode ol Lu wn gt wn Zz a a rs D2 fa W a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING 5 1 Basic Concept of Redundant System 5 4 5 1 1 Determination of System A System B D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q 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 and communicates with the network The system that includes the CPU module running the programs is referred to as the 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 This backup system is referred to as the standby system The standby system CPU module does not run the programs The same status as the STOP status The control system and standby s
273. cted connected Diagram 6 34 GOT Connection Method Applicable to a Redundant System 6 45 6 3 Communication between the Both Systems CPU Module and GOTs 6 REDUNDANT SYSTEM NETWORKS M als 2G fel series 6 3 1 When connecting GOTs to MELSECNET H remote I O station For MELSECNETI 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 toa 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 station via the RS 232 port TRACKING CABLE ig ij ooo000 ooo000 ooo Colas ols ojja TIT as C a E ogad E G Cole ieste
274. ction means that the redundant CPU checks for its own error i 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 2 Error Detection Processing aie 2S a Error detection processing When detecting an error the redundant CPU will perform the following process 1 Turning the ERR LED etc on M 2 Turning the special relays SM0 SM1 on a 3 Storing the error information error code into the special resistor SD0 z 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 programmable controller or machine system interlock fi x y Og gt b Error history confirmation ae The redundant CPU records the 16 latest error codes as error history RET The error history can be checked in the PLC diagnostics of GX Developer 23 The error history is backed up by the battery even if the programmable controller is powered off ol 3 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 Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le 1 Stop
275. ctor from the I O module l Replace the Standby System s I O Unit CONFIGURATION SYSTEM 1 Disconnect the I O module from the main base unit 2 Mount an alternative I O module the same model as the control system I O module to the main base unit TRACKING CABLE Refer to the QCPU Module User s Manual Hardware Design Maintenance and Inspection for mounting removing the I O module Mounting the Terminal Block Connector to I O module Mount the terminal block connector to the I O module Turn on the Standby System 1 Align the position of the standby system CPU module s RUN STOP switch with that of the control system RUN STOP switch 2 Set the 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 ON green and that power is being supplied properly REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM FUNCTIONS Start standby system Diagram 8 28 I O Module Replacement Procedure REDUNDANT SYSTEM NETWORKS POINT When the standby system is powered OFF the control system CPU module develops ina 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 Refe
276. cy check Operating status consistency check settings 5 20 Operation status consistency Check eeeeeeeeeeeee 5 19 Parameter valid drive settings consistency check erccccccccccccccccccccccccccscccccccccccccccsccccoccccsees 5 D5 Consistency check execution conditionsessessesse 5 1 7 Consistency check points evcccccccccccccccccccoscsccee 5 16 CONTENTS ccccccccccccccccccccccccccccccccccccccccccees 1 11 INDEX 1 CONTROL EXE esecccccccccccccccccccccccocccccoseseeee 5 34 Control system crerecececcceccccccccccccccccecsceces 1 22 5 5 Control standby status flag SM1515 sesseseeseseses 5 7 Control standby status flag SM1516 sesseseeseseses 5 7 D Debug MOE eeccecccccccccccccccccccccccccccccccccccccces 5 13 Determination of control system and standby system cocoocooococooooooooooooo0000000000000000000000000000000000000 D_D When only one system starts Upseeseesceseeseecees 5 7 When system A and system B start up simultaneously coooooooooooooooo00000000000000000000000 5G When system A starts up first eeeeeseeeeesseeeees000 5 5 When system B starts up first eeeeeseeeeesseeeees000 5 6 Determination of system A system B eeeseeseeseeeese 5 3 Disconnecting a tracking Cable sseesseseeseeeeseeseese 3 4 Display of Write to PLC screen eeeeeeeseessesoeeoo00 4 14 E Enforced ON OFF of external I O seeeeeseeeeoo000 5 427 Error CHECK eecccccccccccccccccccccccccccccccccccccccccccce 4 6 Error code 6120 eccccccccccccccccccccccccccccccccccc
277. d the control system CPU module scan time will extended Refer to the following manual for information on control system CPU module scan time extension QCPU User s Manual Function Explanation Program Fundamentals Signal Flow Processing The signal flow in the changed steps or program turns on Therefore if a running program is changed online the rise fall and SCJ instructions will do the following 1 Rise instruction PLS instruction 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 Fall instruction LDF ANDF ORF MEF PLF If the execution condition is off when online program change is complete the fall instruction will be executed again 2 3 SCJ instruction If the execution condition is on when online program change is complete a jump to the specified pointer will be executed without waiting 1 scan 5 6 Online Program Change for Redundancy 5 6 2 Program Change While CPU is Running REDUNDANT SYSTEM FUNCTIONS MELSEC KE eries j Consistency check between both systems during online program change 1 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 pro
278. dant system Explains the troubleshooting methods and module replacement in a redundant system Explains the processing time of a redundant system 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 L gt 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 below LC Qn H QnPH QnPRHCPU User s Manual Function Explanation Program Fundamentals HOW THIS MANUAL IS ORGANIZED Reference destination Chapter heading A reference destination or The index on the right side of the page shows the chapter of the open page at a glance reference manual is marked ae ae 5 REDUNDANT SYSTEM FUNCTIONS MELSEC E sees 2 Confirming system A System B Identify system A and system B by checking the SYSTEMA and SYSTEM B LEDs of CPU modules OVERVIEW TableS 1 Identify system A and system B by checking the SYSTEM A and SYSTEM B LEDs CPU Module LED LED Statuses LEDName SystemA System B SYSTEMA OoN oF SYSTEMB OFF ON CONFIGURATION SYSTEM Refer to the following manual for details on the CPU module LED QCPU User s Manual Hardware Design Maintenance and Inspection _ 3 Precautions W
279. data 2 END T Run END o Run END gRun joRun program 3 program 4 program 5 program 6 Send H Send 4 Tracking 4 Tracking processing 2 processing 3 Receive Receive END Run program 1 Run program 2 o Run program 3 o Run program 4 Adjust Tracking data 1 data 2 Diagram 5 57 Tracking Operation Timing in Separate Mode 5 5 Tracking Function 5 5 7 Tracking Mode Adjust Tracking 5 94 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG Q 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 Reception of Tracking Data Receiving Tracking Data 4 Completed System
280. dby system System A and System B L gt Table6 1 Transfer Setup A Pi lil Y fa CCIE Cont NET II CE Link Ethernet PLC NET 10 H board board board board board fi CCIE Cont MNET II CC Link Ethernet C24 G4 NET 10 H module module module module module PC side I F PLC mode 9 QCPU Qmode Other ee Connection channel list station Li No specification Other station Single network Other station Co existence network PLC direct coupled setting Specify a Time out Sec fio Retry times jo ae destination onnection test Target system system Not specified Zi PLC type C24 CCIE Cont NETMI CC Link Ethernet fro system NET 10 H Standby system Dwal System amp System B System image Co existence network route Line Connected Q A6TEL C24 C24 CCIE Cont NET II CC Link Ethernet NET 10 H Accessing host station Diagram 6 1 Connection Setup Screen 6 1 6 1 Communication with GX Developer and PX Developer 6 1 1 Communication Methods with GX Developer 6 REDUNDANT SYSTEM NETWORKS M als 26 fel ceries
281. digits of serial No is 06082 or later 120 x 10 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 2 System Switching Time 9 8 APPENDICES APPENDICES MELSEC TA eries Appendix 1 Comparison of Q4ARCPU and QnPRHCPU 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 Tracking Time QnPRHCPU Redundant System Internal device 48k Word Setting Time Q4ARCPU Redundant System Internal device 48k Word Setting Time Synchronized Tracking Mode 41 ms gi e Batch Transfer Mode 68 4 ms Performance Program Priority Mode 21 ms a e 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 CoE Auto Refresh Applicable Maximum 4 Modules NA Eerformed using FROM TO Setting instruction lt lt First 5 digits of serial No is 09011 or earlier gt gt 11 modules Main base unit only System Configuration Maximum Number of Extension Base Unit Modules Mounted on Main q Modules which a
282. dule POWER LED is lit green and that power is being supplied properly l Start standby system Diagram 8 24 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 39 8 3 Replacing Module in Redundant System 8 3 2 Power Supply Module Replacement Procedure 8 TROUBLESHOOTING MELSEC KE eries 8 3 3 Redundant Power Supply Replacement Procedure When a pair of redundant power supply modules is used in each system one redundant power supply module can be replaced at a time after powering off the module while the redundant system is running This operation can be performed in both systems System control can be continued while the power supply module is being replaced because another power supply module supplies power to the modules mounted on the same base unit OVERVIEW Redundant Power supply module Control Standby system system a 2 CONFIGURATION SYSTEM oooooo nooo oooo00 ooo oje on a O Ky
283. dule to Network Module 1 Y SB SW Refresh from Network Module to CPU Module 2 SB SW Refresh from CPU Module Does not execute to Network Module 2 Executes the function Executes the function the function Inputs it Inputs it Does not input it Executes the function Executes the function 41 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 L7 Q Corresponding MELSECNET H Network System Reference Manual Remote I O network gt CC Link System Master Local Module User s Manual 2 Indicates refresh of SB Link special relay SW Link special register used for CC Link IE Controller Network MELSECNET H PLC to PLC network MELSECNET H Remote I O network and CC Link 5 71 5 4 Operation Mode Change Function D REDUNDANT SYSTEM FUNCTIONS M aL 26 fel ceries In Separate Mode Control System Standby System During Normal RUN During 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 function Does not execute refresh from CPU module to function network module Executes t
284. e Section 7 2 Program tandby Ti Standby Type Not executed Program Interrupt Executes when the interrupt factor is established Refer to Program Section 7 2 New Standby System CPU Module Stops program execution Tracking Starts tracking to the new standby system Starts reception of tracking data 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 Writing files in RUN Continues the write operation 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 Initial Device Value Setting Special Relays and Special Registers 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 Does not set the value Holds the data However stores the statuses of control system and standby system after system switching in SM1515 and SM1516
285. e and DeviceNet slave module For intelligent function modules dedicated instructions and interrupt pointers are not usable 41 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 System Configuration APPENDICES MELSEC TA eries Table App 3 Comparison of Qn H CPU and QnPRHCPU Continuation Item QnPRHCPU QnHCPU 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 Applicable Connection the GOT only Computer Link on N A Applicable Ethernet TEE Applicable Applicable CC Link IE Controller Applicable N A for extension base unit Applicable GOT Network Connection Connection Type MELSECNET H PLC to PLC Applicable N A for extension base unit Applicable Network Connection CC Link F Connection Applicable Applicable MELSECNET H Remote I O i i Seim Applicable N A for extension base unit Applicable Connection Disabled Slot 1 becomes I O number 0 Mounting I O module or Mount I O
286. e EIEE a e System type Control system Operation mode Backup mode 5 a a 5 el P A a el E e Operation Specify execution destination am c Gae so y C Currently specified station a a 5 a E zj a pm _ pam i C Al stations tal LA al 8 C Extract memory card Es z C Spec icgow I Baik gales BLE Tracking cable 2i GX Developer RUN STOP STOP Control system Standby system a a Tanp Hann 5 al z le al iS el gl 8c g e aj E e e ay fa Ho E z e E Gl fe H g a fe Tracking cable GX Developer Diagram 5 100 Remote STOP Operation When Both Systems Are Specified Redundant CPU Functions Restricted in Redundant System 5 10 2 Remote Operation for Redundant System D REDUNDANT SYSTEM FUNCTIONS M aL 26 Kel ceries 3 Remote reset operation a In the backup mode S a In the backup mode performing remote reset operation for
287. e 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 51 8 3 Replacing Module in Redundant System 8 3 9 Tracking Cable Replacement 8 TROUBLESHOOTING MELSEC KE eries 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 37 CONFIGURATION SYSTEM l Checking the system where the extension cable to be replaced is connected TRACKING CABLE Check that the extension cable to be replaced is connected to the standby system CONTROL LED is turned OFF When connecting an extension cable of the control system switch system to the standby system by GX Developer Turning OFF power supply of standby system PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM Replacement of an extension cab
288. e System Switching Operation After System B Power Switching Pisa Ae Switching w Method Switching Condition Condition OFF gt ON 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 Standby Standby Standby Watchdog Timer Startup as control system System System System System Control Standby Standby Control Hardware Failure Startup as control system Automatic System System System System System Control Standby Standby Control SN Power OFF Startup as control system Switching System System System System i Control Standby Standby Control Reseting Startup as control system System System System System System Switching Control Standby Control Standby System switching will cause system B to Request by Network System System System System become control system Module System Switching Control Standby Control Standby Startup as standby system Manual Using GX Developer System System System System System System Switching by rA os Control Standby Control Standby Switching System Switching Startup as standby system System System System System Instruction 5 3 The System Switching Function 5 48 5 3 3 System Switching Execution Possibility SYSTEM PROCEDURE FOR STARTING UP A TRACKING CABLE CONFIGURATION OVERVIEW REDUNDANT SYSTEM ol Lu E n gt N i Z lt Q Zz
289. e control system and standby system so that they will be consistent in the followings TRACKING CABLE e Model and type of modules mounted in the control system and standby system main base units e Network module mode settings 1 Ifa 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 REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A 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 ol e 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 main base unit Lu wn gt wn Zz a a rs D2 a Lu a o Z O O Z U e Connect OUT connector of the redundant type extension base unit to IN A W connector of the redundant power extension base unit 9 e The main base units used in systems A and B should be the same model Ea 1X aia Table5 15 Error description when extension base unit does not meet use condition 5 z W W Use condition Error description SE Connect the redundant
290. e 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 TO Y10 Scan execution type Prepare tracking Program transfer data Prepare tracking PROCEDURE FOR STARTING UP A 1 1 1 1 1 Wait Wait transfer data 1 0 END 0 7 END 0 Control system CPU module Sar ieee i 1 l IE 1 Send _ 1 Send m _ Send Tracking transfer processing SP Tracking transfer processing i Receive _ 1 Receive Receive Scan execution type Scan execution type f f i 5 i m program program Standby system CPU module i eens oO y END END 0 g m BA jh I l New control system CPU module Reflect tracking Output Reflect tracking Output i Output j Output data transfer data transfer 1 i 1 1 I I i 1 1 OUT TO OUTTO out To outto END processing END processing END processing END processing Program i i ON i It ON 1 Sana e a D p wo ft I i l i l l l l ON TE i ON p i l Coil of TO I i i T T Le Bi ON I I Contact of T
291. e password registration is irrelevant Checks the initial device value file set in the PLC parameter PLC file Initial Device Values settings 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 1 Parameters CONFIGURATION SYSTEM Programs TRACKING CABLE 1 If the 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 REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A b Inconsistency Errors Table5 12 shows the file inconsistency errors occurred when the target files are inconsistent ol Table5 12 File Inconsistency Errors Execution Conditions Error Description e When both systems are powered ON simultaneously When both system CPU modules are unreset RESET L CLR switch is set to the neutral position simultaneously When one system starts up after the other When the separate mode is changed to the backup mode Lu wn gt wn Zz a a fa W a
292. e same as those of the control system fi Refer to the QCPU User s Manual Hardware Design Maintenance and Inspection for gt mounting modules Z g zo Be rz 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 D 4 Mount the terminal block connector to the I O module g 5 Connect the extension cable for mounting to the main base unit of the standby system g z o e o zZ O O ol w l D 2 O hA 8 3 Replacing Module in Redundant System 8 46 8 3 6 Main Base Unit Replacement Procedure 8 TROUBLESHOOTING MELSEC TA eries Turn on the Standby System s Power Supply 1 Align the position of the standby system CPU module s RUN STOP switch with that of the control system 2 Set that standby system CPU module s RESET L CLR switch to the central position reset switch neutral position 3 Turn the standby system s power supply ON Confirm the Power Supply Module s POWER LED Confirm that the power supply module s POWER LED is it green and that power is being supplied properly Start standby system Diagram 8 34 Main Base Unit Replacement Procedure 4 POINT When the standby system is powered OFF the control syste
293. e settings 2 Up to 8 half width characters File name i l a Cannot include the following characters 9 fii lt gt t5 5 wW a z 5 5 Tracking Function 5 82 Z 5 5 4 Tracking Data Settings D REDUNDANT SYSTEM FUNCTIONS 5 83 MELSEC TE eries 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 x 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 track
294. e the Control system o Also if the control system is already on the other system will be the Standby system when it starts up Control system oooo00 ooo ooo000 ooo ejeje BHE i Be i SH O RHE P 308 ele H 8 H e Tracking cable Turn on the power Leave the power in OFF position Diagram 5 7 Control System when Only One System Starts Up 6 The STANDBY SYS DOWN error code 6300 continuation error will occur in the control system CPU module By disabling Check standby system malfunction at the standby System Monitor settings in the redundant parameter operation mode settings with GX Developer the control system will not detect the STANDBY SYS DOWN continuation error 4 Confirming the Control System Standby System Identify the control system and standby system by checking the CONTROL LEDs of CPU modules Table5 3 Confirming the control system and standby system by checking the CONTROL LEDs CPU module LED LED status Q12PRHCPU Control Standby move J LED Name Run Fo System System a CONTROL BAT BooT L Refer to the following manual for deta
295. e tracking cable has been disconnected while the CPU module is 9 SYSTEM ALED normally operating as system A z Flashing until the system A connector of the tracking cable is 2 connected 29 Off Not operating as system A i e operating as system B The SYSTEM B ae LED is On raed 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 g 10 SYSTEM BLED Flashing until the system B connector of the tracking cable is zg connected 9 E Off Not operating as system B i e operating as system A The SYSTEM A SL LED is On Debug mode o e o zZ e O ol w l D 2 O hA 8 TROUBLESHOOTING MELSEC TE cries 8 1 Troubleshooting Flow This section provides the troubleshooting for each possible case Section 8 1 4 To the flow for when the RUN LED does not light up Error Details The MODE LED does not light up The BACKUP LED is lit up solid red YES The SYSTEM A B LED is lit Si TRACKU oie solid red The SYSTEM A B LED is flashing HT Usb ad eae lal sae Section 8 1 4 To the flow for when the RUN LED does not light up Section 8 1 5 To the flow for when a system switching has occurred The system switching could not be sone gt Section 8 1 6 Mee for when a system switching could not be Diagram 8 2 Troubleshooting Flow NO
296. ecutable Inexecutable Inexecutable not occur Intelligent function module e SM1593 OF F Executable Executable Inexecutable St UL GL Op error Buffer memory batch At END 9 9 4 4 Monitor monitor device batch Executable Executable Inexecutable Inexecutable processing Oiio 5 139 5 11 Access to Module Mounted on Extension Base Unit To the next page D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries Table5 65 Access to Module Mounted on Extension Base Unit Continued Execution timing Dedicated Dedicated Atinstruction Intelligent function module Access from control system Access from standby system Backup mode Separate mode Backup mode Separate mode Inexecutable Inexecutable Inexecutable Inexecutable instruction instruction execution ULNGC 4 CC Link IE Controller Network MELSECNET H module cannot be mounted to the extension base unit 2 An error code 4248 is returned to the request source when system switching occurs during monitoring 3 An error OPERATION ERROR 4122 occurs 4 Accessing to a module mounted on the extension base unit from the standby system is disabled When buffer memory batch monitor or device batch monitor is executed from GX Developer the following message box is displayed 1 When executing buffer memory batch monitor 2 When executing device batch m
297. ecute 5 5 Refresh processing Output from output module Execute Execute Not execute Not execute Direct access of input Executable Executable Inexecutable Inexecutable I O access 3 device DX n Atinstruction Instruction Direct access of output execution Executable Executable Inexecutable Inexecutable device DY I O refresh instruction Executable Executable Inexecutable Inexecutable Refresh of intelligent Executable Executable Inexecutable Inexecutable function module Refresh of CC Link IE 4 4 4 4 Inexecutable Inexecutable Inexecutable Inexecutable Controller Network module Refresh of MELSECNET H 4 4 4 4 Inexecutable Inexecutable Inexecutable Inexecutable module Refresh AUEND Refresh of CC Link master processing Executable Executable Inexecutable Inexecutable module Device initial value of link 2 F Inexecutable Inexecutable Inexecutable Inexecutable direct device JL_ _ Device initial value of REESE Ve intelligent function module Executable Executable Inexecutable Inexecutable buffer UL GL memory ae Data link instruction Executable Executable Inexecutable Inexecutable Refresh instruction Executable Executable Inexecutable Inexecutable Read write from to e SM1593 ON Atinstruction intelligent function module Executable Executable Inexecutable Inexecutable ia execution special function module An error does Link direct device JM Inex
298. ecute it again after confirming the state of the tracking cable lt E5 010a4242 gt 5 7 Memory Copy From Control System To Standby System 4241 will be stored in SD1596 of the control system CPU 42424 will be stored in SD1596 of the control system CPU 5 122 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu wn gt wn Zz a a Zz fa W a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS MELSEC TE cries 5 8 Online Module Change Hot Swapping 5 123 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 1 O module mounted on the main base unit where the Redundant CPU is mounted Only when the extension base unit is not connected 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 s
299. ed a system switching e Diagram 5 93 the processes that take place when a malfunction occurs on both networks with network module redundant group settings f E OPS OPS Control system 5 Sonmuz 5 comz Standby system Standby system Comin F Commi Control system SySIem error Z error System B System A error error System B ig 3 d TE F 1a E O EL E e ell 3B F D B Tracking cable Tracking cable group setting have requested a system switching Both modules set in the network module redundant Systems will switch Diagram 5 93 Operation When Error Occurs on Both Networks 5 125 5 9 Network Module Redundant Group Settings D REDUNDANT SYSTEM FUNCTIONS MELSEC KE cries 2 Redundant Group Settings Redundant group settings are made in the network parameter group settings using i GX Developer gt Set Group or leave it block in the network module set to the lower I O No g Network module redundant group settings Module No Start 1 0 No
300. ed 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 Function 5 5 4 Tracking Data Settings D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries 5 5 5 Tracking Block And Tracking Trigger 1 Tracking Blocks i ed Ww 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 x G b Tracking the Tracking Blocks i Set whether the tracking block will be tracked or not with the data tracking block mio specification trigger SM1520 to SM1583 that corresponds to the target tracking z3 block When the data tracking block specification trigger is turned ON the device data set to the corresponding tracking block No will be tracked a Program Example z 3 H SM1521 4 Transfer Tracking Block 2 SM1522 H Transfer Tracking Block 3 y z Oa agg OFS Oza Operation er END Processing END Processing END Processing END Processing 5 Program Program Program Program ae eS ON Ey SM1520 oe a ON ara smis210FF ON z i i i 5 M1522 OFF t L 4 be 5 Block 3 Block 3 Diagram 5 50 Tracking Operation Timing by Tracking Trigger 6 E 2 2 i 3 S 5 5 Tracking Function 5 84 5 5 5 Tracking Blo
301. eeee000 5 380 Precautions when executing the SP CONTSW instruction C0000000 0000000000000000000000000000000000000000 5 40 Precautions when executing the system switching INSTFUCTION eeeseeccccecoo00000000000000000000000000000000 5 40 Previous control system cccooooooooooo0o00000000000 App 26 Procedure for mounting modules eeeesseeeeeesseeee 4 6 Procedure for starting up a redundant systemesses 4 1 Processing LITNE eececccccccccccccccccccccccccccccccceceses Q1 Program priority MOE eeccceccccccccccccccccccccccceces 5 OD Programming CAUTIONS ceccccccccccccccccccccccccccsoces R Reason for system switching eccccccccccccccccccococes 534 Redundant CPU operation upon an error detection Redundant power extension base Unit eessesseeeeee 1 21 Redundant power main base Unit eeeeseeeeeeeeeeeeee 1 21 Redundant system functions sseeeeeeeeeeseeseeee 5 1 5 32 System switching method eccccccccccccccccccsccceee 5 33 Redundant system OVEIVIEW ceccccccccccccccccccccccce 1 4 Redundant system configuration essessessesessesee 1 4 Redundant type extension base Unitecsseeseesseesees 1 21 Remote I O network eecececccccccccccccccccccccccccccces G Remote latch clear eeecsecsccccccccccccccccccccccccccses 5 131 Remote operation cooooooooooooooooooo0000000000000000 5 1 34 Remote operation for both systems esessesseeeeee 5 133 Remote PAUSE eeecco00000000000000000000000000000 5 1 31 Remote reset eecccecccccccccccccccccccccccccccscccccses 5 3
302. eeeeeeeceossoecceceoococcceoeoococececoeooosececoeosoee G 48 Communication when the GOT is Connected to CC Link IE Controller Network MELSECNET H or MELSECNET 10 PLC to PLC Network eeeeeeeecccccccccccccccccccccccovccccees G 49 When Connecting GOTs to a Ethernet e eeeeseseseeeeeseseoeecoecoococecceoeocsocecceoeosoeeceeoeosseee G 50 6 4 Precautions for Accessing Redundant CPU from Other Networks esseessesecsseccccccscesccccesccccceess G 52 6 5 Precautions for Writing Device Data from Other Station esereresesesessscscscccssceccscccsccescsosososoees G 54 CHAPTER7 PROGRAMMING CAUTIONS 7 1to 7 23 7 1 Instructions Restricted in Use for Redundant System Ccccccccccccccccccccccccccccccccccccccccccoccccoocoooos 7 2 Cautions on Fixed Scan Clocks and Fixed Scan Execution Type Programs serseeseeseesesceececeesees 7 Q 7 3 Precautions for Using Annunciator F in Redundant Systemeeseeseescescesccscccccccsccsccscccccccccess 7 14 7 4 Precautions at System Switching Occurrence cooooooooooooooooooooooooooooooo0ooo00000000000000000000000000 7 7 7 5 Precautions of Programming when Connecting Extension Base Unit e sseeeeesseeeeeesseeeeesosoooo000 7 23 CHAPTER8 TROUBLESHOOTING 8 1to 8 52 8 1 Troubleshooting Flow ooooooooooooooooo00000000000000000000000000000000000000000000000000000000000000000000000000000 J ia 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 8 1 13 8 1 14 8 1 15
303. efer to each network module manual for details on a specific network module operation 5 3 The System Switching Function 5 52 5 3 4 Both Systems Operations After System Switching OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS Device No MELSEC kaser 5 3 5 Special Relays Registers For System Switching System switching enable disable 1 Special Relays For System Switching Special relays for system switching are shown in Table5 38 Table5 38 Special Relays For System Switching 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 Setting at Time of System Switching New Control System New Standby CPU Module System CPU Module SM1590 G flag from network SD1590 D O 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 SM15914 error detection This applies to the following switching methods _ O Device No SD5 disable flag at system switching Error common information e System switching from GX Developer
304. efore 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 23 For the I O signal is X Y80 to X Y9F X9E X9F Write 1 in units of bytes to iE bt f LTOP H8 H96 K1 K1 buffer memory address 96H Diagram App 23 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 App 33 Appendix 6 Precautions for Using Serial Communication Module Appendix 6 1 CSET Instruction APPENDICES MELSEC KE eries 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 PROCESSING TIME FOR REDUNDANT specifying the head address and area size a wn 1 W O signal Table App 16 List of I O Signal V O signal i SR Signal name Description CH1 side CH2 side X n 1 E Q series C24 ready ON Accessible s ON Module error occurred 8 Watchdog timer error j fa X n 1 F OFF Module being normally ia WDT error a operated z 2 Buffer memory Table App 17 List of Buffer Memory Buffer memory address Hexadecimal decimal CH1 side 03 a PIT 3 Buffer memory name A2 4 162 142 322 Mransmission buter memory head 7 address designation a zZ A3p 163 1434 323
305. efresh settings 256 Appendix 3 Comparison of QNPHCPU and QnPRHCPU App 10 APPENDICES MELSEC TE cries Table App 6 Comparison of QnNPHCPU and QnPRHCPU Continued System Configuration Programming Tool Item QnPRHCPU QnPHCPU Multi CPU System N A Applicable Single CPU System Applicable Debug mode only Applicable Bus Connecion N A Applicable CPU Direct Applicable Communication with the CPU module Applicable Connection connected to the GOT only PP Computer Link J COA N A Applicable Ethernet Gannection Applicable Applicable CC Link IE Controller Applicable N A fi tension b it Applicabl GOT Naana pplicable or extension base unit pplicable Connection z Connection Type MELSECNET H PLC to PLC f Applicable N A for extension base unit Applicable Network Connection CC Link Connection Applicable Applicable MELSECNET H Remote I O Station Applicable N A for extension base unit Applicable Connection Moemin No moaier Disabled Slot 1 becomes I O number 0 i ee eee i sloto Mount I O modules and network modules on slots Enabled 1 and later Restriction on the Applied applicable intelligent The Ethernet modules and MELSECNET H Not applied function modules GX Developer PX Developer module of serial No 06052 or later are applicable Version 8 18U or later is applicable Version 1 06G or later is applicable Version 7 or later is applicable Versi
306. em B Start Up Simultaneously iia If system A and system B start up simultaneously system A will be the Control w system and system B will be the Standby system lt If the system A and system B CPU modules are reset RESET L CLR switch is set to z the RESET position and unreset RESET L CLR switch is set to the neutral position lt simultaneously system A will be the Control system and system B will be the Standby system Control system Standby system z E Oa System A System B u a i i B g aol ije 5 i ai a 2 4 E g 5 B BES J B PER z one a 3 5 Tracking cable Power on both systems simultaneously Diagram 5 6 Control System and Standby System when System A and System B Start Up Simultaneously Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le 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 E s seconds of the other Z rd zo Be W Ww eZ o zZ o 56 z3 ao zZ fe E N 5 a 5 a 5 1 Basic Concept of Redundant System 5 6 5 1 2 Determination of Control System and Standby System D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries 3 When Only One System Starts Up Whichever system that starts up first will b
307. em CPU module E MELSOFT application e Tracking cable disconnection N EE E J Please execute it again after confirming the state of the tracking cable e Tracking cable failure lt ES 010a4242 gt 42424 will be stored in SD1596 of the control system CPU module The following error dialog box will appear e USB cable disconnection ES MELSOET application i Cannot communicate with the PLC Execute again after checking the connections with the PLC RS 232 cable disconnection lt E5 01808201 gt 5 Precautions 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 2 Program memory to ROM 3 PC write flash ROM 4 CPU module write during RUN 5 System switching 6 Operation mode change 5 121 5 7 Memory Copy From Control System To Standby System D REDUNDANT SYSTEM FUNCTIONS b Execution Conditions Memory copy executed to the standby system CPU module Restrictions on Memory Copy MELSEC TE cries 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 Operation Memory Copy Using Special Memory Copy Using GX Developer 4 i Relays and Special Registers The following error d
308. em CPU module can be performed even when system switching occurs This communication can be performed by MC protocol only Station Multiplexed Remote Master Station Multiplexed Remote Sub master System A System B Control System Standby System ic ooo ooo000 Coig Tracking cable activated System switching j Remote I O module Serial communication module ti When specifying System A using MC protocol Multiplexed Remote Sub master Station Multiplexed Remote Master Station System A Control System System B ooo ooo000 Standby Syste 3 m oooooo U GAIMANA SEES lez AA ty MELSE
309. em Does not Exist 2 When the corresponding error code is stored in SD1649 and error clear is 8 33 8 2 Error Clear 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 TROUBLESHOOTING M eLS 26 Fel series 3 If an error has occurred due to a problem other than that of the CPU module it will not be removed even when clearing the error is attempted using SM1649 and SD1649 Example The cause of the SP UNIT DOWN error cannot be removed by performing error clear operation using SM1649 and SD1649 as the error could have occurred in a base unit including extension cables network module etc Remove the cause of the error by referring to the error code list OVERVIEW 4 If the cause of the error is not removed after error clear has been performed the same error will be detected CONFIGURATION SYSTEM 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 Program for Clearing St
310. em Switching seseeeeeeeeseseeeeesesssesesecesecesesececeeseseee 5 51 5 3 5 Special Relays Registers For System Switchinge eeeeeeeeeeseesesesesesesesesesesesecececeesesesosose 5 53 5 3 6 System Switching Precautions e eseeeseseseseeesececececeecocoeoooocoooooesesecesesesecececeesesesossse 5 5G 5 4 Operation Mode Change Function eeeseeeeeeeeeseseseseeeseececececccecececeococcoosoeoososoosesssesesesesee 5 58 55 Tracking Function COCO COOO OOO OOOO OOO OOOO OOO OOOO OOOO OOOO OOOOH OOO OO OOOOH OOOO OOO OOOO OO OOO OOO OOOO OOOO OOOOOO OOOO OOCE 5 73 5 5 1 Tracking Function Overview CO COOOO OOOO OOO OO 00000000000000000000000000000000000000000000000000000000000000 5 73 5 5 2 Tracking Execution ProcedurEe ececcccecocooo00000000000000000000000000000000000000000000000000000000000 5 76 5 5 3 Tracking Data COCO OOOO OOO OOOO OOO OOO OOOO OOO OOOO OOO OOOOH OOOO OOO OOOOH OOOO OOO OOO OOOO OO OOO OOOOH OOOOH OO OOOO OOOO OOOOE 5 7T 5 5 4 Tracking Data Settings 0000000000000000000000000000000000000000000000000000000000000000000000000000000000000 5 s 82 5 5 5 Tracking Block And Tracking TriggEr eeseeeeeeeecececcccccccocoococoococecccccccccccccccccccocoocoocoooo 5 84 5 5 6 Tracking Execution e eeeccecccooco00000000000000000000000000000000000000000000000000000000000000000000000000 5 88 5 5 7 Tracking Mode COC COOO OOO OOOO OOO 000000000000000000000000000000000000000000000000000000000000000000000000000000 5 90 5 5 8 Device Data
311. emains the ON OFF status according to the forced ON OFF information of the control system CPU module Lu i gt n Zz a a z fa W a o Z O O Z Le 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 REDUNDANT SYSTEM NETWORKS 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 PROGRAMMING CAUTIONS TROUBLESHOOTING 5 10 Redundant CPU Functions Restricted in Redundant System 5 130 5 10 1 Enforced ON OFF of external I O D REDUNDANT SYSTEM FUNCTIONS 5 131 MELSEC kaser 5 10 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
312. emarks OFF Module normal X40 Modul E E ON Module error OFF Data link is st d X41 Host data link status m ae eae ON Data linking in progress OFF O ti t ibl X4F Module ready Gii ah ng PaSa z ON Operation possible OFF Not ted SB40C Forced master switching eee ON _ Requested OFF Not instructed SB401 Refresh instructi t standb t itchi 0 efresh instruction at standby master switching ON Instructed p442 Refresh instruction acknowledgment status at OFF Not executed standby master switching ON _ instruction acknowledged 5B443 Refresh instruction complete status at standby OFF Not executed master switching ON Switching complete OFF Not acknowledged SB45A Mast itchi t acknowled t aster switching request acknowledgmen ON Request acknowledged OFF Not complete SB45B Mast itchi t let aster switching request complete ON Complete SW443 Refresh instruction at standby master switching 0 Normal result Other than 0 Stores an error code 1 Indicates the device number on CPU side in 3 of this Section Appendix 4 Sample Programs when Using CC Link App 14 Appendix 4 3 Devices Used in Programs APPENDICES App 15 MELSEC TE cries 3 Refresh Devices In redundant systems refresh of remote inputs RX remote outputs RY and remote registers RWr RWw are set with the program Refresh settings of special relays SB and special registers SW are configured with network parameters The CC Link refresh
313. ement Procedure 8 TROUBLESHOOTING MELSEC Cel ries 2 Replacement Procedure The procedure for replacing the power supply modules is shown in Diagram 8 24 l 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 Removing the wiring Disconnect the power supply cable from the standby system power supply module Replacing the Standby System Power Supply Module 1 Remove the power supply module from the main base unit 2 Mount the alternative power supply module to the main base unit Refer to the QCPU User s Manual Hardware Design Maintenance and Inspection for removing mounting the power supply module 4 Connect the power supply cable to the power supply module t 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 system t Confirm the Power Supply Module s POWER LED Confirm that the power supply mo
314. emory card Control system Execute Station no Host PLC type Q25PRH Operation mode Backup mode Specify execution destination Currently specified station C All stations Specific group collegia Col 1eol Tracking cable GX Developer Diagram 5 105 Remote Reset Operation When Watchdog Timer Error Has Occurred in Standby System CPU Module 5 137 5 10 Redundant CPU Functions Restricted in Redundant System 5 10 2 Remote Operation for Redundant System D REDUNDANT SYSTEM FUNCTIONS MELS eG Q 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 CPU 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 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 RUN Standby SS GX Developer
315. ension base unit s in redundant systems Power supply redundancy is also available by using redundant power main base units or redundant power extension base units Network module CPU module Power supply module Tracking cable MELSECNET H Remote I O network gt Redundantly powered Remote O station Intelligent function module Q68RB A Output module Input module Redundant Power supply module Diagram 1 1 Configuration Example of Redundant System 1 1 Redundant System Overview 1 OVERVIEW M eLS eG lA eries 1 The control system indicates the system that actually controls the redundant system Section 5 1 2 2 The standby system indicates the backup system within a redundant system Section 5 1 2 If an error occurs in the control system the standby system takes over the control of the redundant system 3 Refer to Section 2 3 for details of network modules compatible for redundant system OVERVIEW Pe G E CD Sooo ooo coco ooo g O fae The redundant system described in this manual does not guarantee continuous 2 nO operation of the system depending on the failure status Also when system switching occurs due to an extension base unit error or a module error on the extension base unit the standby system also detects the error and the CPUs on both systems will stop Therefore create a safety circuit exte
316. eption 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 following address Table App 24 List of Buffer Memory Buffer memory address Hexadecimal Setting value Stored value decimal CH1 side CH2 side Switching mode 0001p MC protocol Format 1 90H 1304 TS No specification 0007 Bidirectional protocol 144 Goa a Refer to a OOFF GX Developer connection For mode switching eae Transmission 0000 Set the same setting as the specification 914 1314 specification after setting of GX Developer 145 305 switching Refer to 8000 to 8FFF Set the setting b the same as this area setting For switching setting Switch setting error 0 No error 203 515 and mode switching mode switching Other than 0 Switch setting error confirmation error status mode switching error Appendix 6 Precautions for Using Serial Communication Module App 38 Appendix 6 2 UINI Instruction PROCESSING TIME FOR REDUNDANT SYSTEMS APPENDICES INDEX APPENDICES MELSEC TE eries a Switching mode No specification a
317. er SM1548 Tracking Block No 29 Tracking Trigger SM1549 Tracking Block No 30 Tracking Trigger SM1550 Tracking Block No 31 Tracking Trigger SM1551 Tracking Block No 32 Tracking Trigger SM1552 Tracking Block No 33 Tracking Trigger SM1553 Tracking Block No 34 Tracking Trigger SM1554 Tracking Block No 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 Tracking Block No 41 Tracking Trigger SM1561 Tracking Block No 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 SM1566 Tracking Block No Tracking Block No 46 Tracking Trigger 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 S
318. er 1 is i T100 changed into 0 RST M18 ANE PERRE EPEE E E E E AE E EE AN SETE ES T EA EE S EN E E E 3 M16 M17 M18 317 PE ET J 2 4 Diagram App 26 Program Example 41 When using the Q series C24 function version A add the dotted line to the sequence program 2 Communicate data when M19 is ON App 37 Appendix 6 Precautions for Using Serial Communication Module Appendix 6 1 CSET Instruction APPENDICES MELSEC KE eries Appendix 6 2 UINI Instruction The following shows the device and buffer memory used in the sample program for mode switching 1 Device of programmable controller 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 1 0 signal g Signal name turned ON OFF xn6 XnD Modeswitching o Completed Mode switching y Switching in execution f request Yn2 Yn9 O Table App 23 List of I O Signal I O signal p ae Signal name Description Xn3 XnA Reception data read request ON Requesting read Xn4 XnB Rec
319. er 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 1 Extension of Scan Time due to Tracking 9 4 Q PROCESSING TIME FOR REDUNDANT SYSTEMS M ELSEG Q series 2 Tracking Processing Time Trb Tracking processing time is calculated as shown below 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 Word Table9 4 Number of N1 to N4 Data Transferred Number of Data Transfer Data Transferred Words Time set for redundant gt Number of steps for N1 Signal flow Memory f parameter tracking settings each program 16 N2 SFC Information SFC program execution time 13312 13k Fixed PIDINIT Instruction Execution i 1024 1k Fixed N3 PID Control Instruction Time Information S PIDINIT Instruction 3 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 1 Fractions are rounded up 9 5 9 1 Extension of Scan Time due to Tracking Q PROCESSING TIME FOR REDUNDANT SYSTEMS M als 26 Fel cerie
320. er Station that Controls 4 5 6 CC Link Refer to Appendix 4 for programs that switches 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 Checking the operating status of standby system After power ON the status of CC Link master module on the standby system can be checked with the link special register SW80 of the control system CPU module If the normal data link status of the standby master station the bit corresponding to the standby master station is OFF in SW80 stays ON for two seconds or more the CC Link master module on
321. erial number 10042 This manual has been revised wholly because of integration of existing MELSECNET G network modules into CC Link IE Controller Network module Partial correction GENERIC TERMS AND ABBREVIATIONS Section 1 1 1 2 2 1 2 3 2 4 4 2 5 1 5 1 1 5 3 3 5 3 4 5 4 5 6 1 5 6 2 5 7 5 9 5 10 1 5 10 2 6 1 1 6 1 3 6 3 2 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 6 4 7 1 7 3 8 1 7 8 1 16 8 3 1 8 3 2 8 3 3 8 3 4 8 3 5 8 3 6 8 3 9 9 2 Appendix 1 Appendix 2 Appendix 3 Appendix 4 1 Appendix 5 Addition Section 8 1 12 8 1 13 8 1 14 8 1 15 Mar 2009 SH NA 080486ENG L Paral correction PPR Boo Jul 2009 SH NA 080486ENG M Partial correction ph fiat fren mecavrote cenene Tews wo Aseaevanons Apr 2010 SH NA 080486ENG N Partial correction SAFETY PRECAUTIONS Section 2 3 5 5 1 6 3 Appendix 4 4 Addition CONDITIONS OF USE FOR THE PRODUCT Jun 2011 SH NA 080486ENG O Partial correction INTRODUCTION Section 2 3 Appendix 4 4 4 5 Japanese Manual Version SH 080474 O 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 ELE
322. ersion refer to 2 in this section 6 For restrictions on the number of modules that can be mounted to a main base unit in a redundant z CPU system refer to Section 2 4 a 7 Mountable to extension base units 2 8 Use the Redundant CPUs whose first five digits of serial number is 10042 or later in both 5 systems a 5 E 2 3 Applicable Devices and Software 2 13 2 SYSTEM CONFIGURATION 2 14 MELSEC TA eries b Modules that cannot be mounted to MELSECNETI H remote I O stations Refer to the following manual for the modules that cannot be mounted to MELSECNETH H remote I O stations L gt Q Corresponding MELSECNET H Network System Reference Manual Remote I O Network c Modules that cannot be mounted to extension base units The following modules cannot be mounted to extension base units e CC Link IE Controller Network module e MELSECNET H module e Ethernet module function version B or earlier e Web server module first 5 digits of serial No 09011 or earlier e MES interface module first 5 digits of serial No 09011 or earlier e Interrupt module e PROFIBUS DP master module e PROFIBUS DP slave module e PROFIBUS DP interface module e DeviceNet master module e DeviceNet slave module 2 3 Applicable Devices and Software 2 SYSTEM CONFIGURATION M eLS 26 Fel series 2 Confirming the serial No and function version of the CPU module a On the rated plate The serial No and function versi
323. ery If the battery is dropped or any shock is applied to it dispose of it without using Before handling the module touch a grounded metal object to discharge the static electricity from the human body Failure to do so may cause the module to fail or malfunction Disposal Precautions CAUTION When disposing of this product treat it as industrial waste When disposing of batteries separate them from other wastes according to the local regulations For details of the Battery Directive in EU member states refer to the QCPU User s Manual Hardware Design Maintenance and Inspection Transportation Precautions CAUTION When transporting lithium batteries follow the transportation regulations For details of the regulated models refer to the QCPU User s Manual Hardware Design Maintenance and Inspection CONDITIONS OF USE FOR THE PRODUCT 1 Mitsubishi programmable controller the PRODUCT shall be used in conditions i where any problem fault or failure occurring in the PRODUCT if any shall not lead to any major or serious accident and ii where the backup and fail safe function are systematically or automatically provided outside of the PRODUCT for the case of any problem fault or failure occurring in the PRODUCT 2 The PRODUCT has been designed and manufactured for the purpose of being used in general industries MITSUBISHI SHALL HAVE NO RESPONSIBILITY OR LIABILITY INCLU
324. eveloper change procedure UL Se E y Diagram 1 11 Online Module Change Hot Swapping of I O Modules mounted on a Main Base Unit a x one Ie oO N 10 System status can be monitored we Dok aves The operation status of the whole redundant system can be monitored using the g z x F Oxa System Monitor of GX Developer raam Control system Standby system a PI a e B fe a g a 3 s D d gl fice ils Z a E oy A E E a ol e C a gj e Zw z a Sieg z g e lt Z faye Ze Tracking cable as Ww gt ew System Monitor Installed status Base 23a 1 4 Base Module MasterPLC gt Main base m n Powe Q25PRH Q371 QJ61 Unmoj gt w i een ata ee GX Developer PEP Backup mode Fal Z 2 ao 2 86 Be WW Ww f rz UH _ ___ _ Standby system Parameter status Mode i0 Address 0 20 40 60 System monitor 1 2 3 4 Online module change eg ey beg None Der 3 ent eee eee Go Module s Detailed Information Z Base Information o rA Sie Product Inf List E fe B Module system error E Module error Module warming Detailed inf of power supply 2 5 E Module change EE Eor in connected system Stop monitor Close x Diagram 1 12 System Monitor of GX Developer 9 zZ fe E N WwW l a 5 1 2 Features 1 15 1 OVERVIEW MELSEC Aries 11 Compact Redundant System The space of control panel can be saved as Q series modules other than the CPU module redundant po
325. eveloper will turn off this relay before starting memory modules copy Turn on this relay when not copying memory from Specific to control SM1598 standard ROM User system CPU module Default Off Execution of standard ROM memory copy Stores the status upon completion of memory copy Stores the same value as SD1596 Applicable to both Backed up for a power failure this register is not A A control system and SD952 initialized when power is switched off and then on or the System En a standby system CPU RESET L CLR switch is moved to the reset position and anil modules Special then to the neutral position Registers It is initialized by latch clear operation Store 3D1H standby system CPU module I O No into Specific to control D1595 User this relay before turning on SM1595 system CPU module Applicable to control This relay stores the status upon completion of memory SD1596 System system and standby copy 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 7 Memory Copy From Control System To Standby System 5 112 OVERVIEW C
326. evices a Communication by MC Protocol and Data Link Instructions For MC protocol external devices can communicate with the specified system i e control system standby system system A or system B OVERVIEW b Communication by Fixed Buffers and Random Access Buffers For fixed buffers and random access buffers external devices can communicate with the control system Ethernet module only as processing via sequence programs is necessary CONFIGURATION SYSTEM 2 External Device Operation at System Switching When system switching occurs in a redundant system external devices operate differently according to the communication method a In the case of OPS connection When system switching occurs in a redundant system the OPS automatically switches the connection path and continues the communication TRACKING CABLE Example Diagram 6 22 shows the external device operation when the control system Ethernet module detects a communication error OPS LJP REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A System A Control System System B Standby System A REDUNDANT SYSTEM FUNCTIONS RS oooooo nooo m switching request Ji g mn O ez
327. extension base unit Generic term for the Q63B Q65B Q68B and Q612B extension base unit Another name for the Q68RB redundant power supply base unit Another name for the Q65WRB extension base unit for redundant system Generic term for the Q3 _ B and Q3L JRB Generic Term Abbreviation Description Extension base unit Generic term for the Q5 _ B Q6L B Q6L_ RB and Q6 _ WRB Slim type main base unit Another name for the Q3 _ SB Redundant power main base unit Another name for the Q3L RB Redundant power extension base Another name for the Q6_ RB unit Redundant type extension base Another name for the Q6L WRB unit Generic term for the 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 Generic term for the QC05B QCO6B QC12B QC30B QC50B QC100B extension cables Tracking cable Generic term for the QC10TR and QC30TR tracking cables for Redundant CPU Generic term for the Q61P A1 Q61P A2 Q61P Q61P D Q62P Q63P Q64P and Q64PN power supply modules Extension cable Q series power supply module Slim type power supply module Abbreviation for the Q61SP slim type power supply module Redundant power supply module Generic term for the Q63RP and Q64RP redundant power supply module Generic term for the Q series powe
328. f the CPU module is OFF 2 If the ERR LED is ON flashing check the error cause using the System Monitor or diagnostics of 2 GX Developer and eliminate it mia nz chs POINT When switching power on again switch power on more than five seconds after switching power off Failure to do so may cause an inrush current of higher than z the specified value to flow 3 rA z O E A Running CPU Module Refer to Section 4 11 1 Set the RUN STOP switch of the CPU module the CONTROL LED is ON to the RUN position and confirm that the RUN LED is ON 2 Confirm that the ERR LED of the CPU module is OFF If the ERR LED is ON flashing check the error cause using the System Monitor or ii E v gt a z lt fa 2 fal Ww ind 5 lt ws az Ob a diagnostics of GX Developer and eliminate it If the error is caused by the parameters or programs correct the parameters or programs a E Restarting System Refer to Z z Section 4 8 Bis Power off the system and then power on again or set the RESET LCLR switch of the CPU module a to the RESET position and then set it to the reset switch neutral position Ei Complete E 12 Diagram 4 2 Procedure for Starting Up in Debug Mode Eoy 1 Use double shielded coaxial cables when configuring a coaxial bus system on a MELSECNET H TE remote I O network Refer to the following manual for the double shielded coaxial cable
329. ference section instruction Sets initial setting of the unit word byte of the number of send receive Applicable Appendix 6 1 data and the send receive area size Performs PLC CPU monitoring registration PLC monitoring cancel to use A CSET roe N A fa the PLC CPU monitoring function Z Clears receive data without stopping the send processing in the Applicable Appendix 6 1 nonprocedural protocol UINI Switches mode transmission specifications and host station number Applicable Appendix 6 2 Receives data in the interrupt program by the nonprocedural or BUFRCVS Aa nee 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 n INPUT 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 N OUTPUT ae 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 en Applicable Appendix 6 9 communication
330. following range Module fixing screw M3x 12 screw Tightening torque range 36 48 Necm 4 6 4 1 Mounting Modules 4 PROCEDURE FOR STARTING UP A REDUNDANT Se M IES 26 FY aries 4 2 Wiring 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 O Install the wiring to an I O module by referring to the following manual as the wiring g 20 method differs according to the model Er rae gt O L gt I O Module Type Building Block User s Manual ae 1 Wiring to a Power Supply Module Connect a power cable and ground cable to the power supply module on a main base z unit by referring to the wiring example shown in Diagram 4 4 S o z pai LineB 100V 200VAC AC 3l z e on Main base unit Q35B Main base unit Q35B 4 Q62P CPU module CPU module x b 2 lt wor DOK ERR ERR 30 A m ja 100V 200VAC ep WEZ e
331. formation 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 System A CPU module System B CPU module Control system Standby system Mo MO m Hy H Hyro Abort tracking transfer due to run write operation requested from within GX Developer Circuit is added to SystemACPU module When M0 is set to ON Y100 is also set to ON Set Y100 external output to ON Refresh to the network module Mo Mo H 100 4 Y100 l C H Mo N 0 m 4Y100 Y100 H Perform system switching due to a stop error in the control CPU module Control system Standby System Standby system Control System System B CPU module s Y100 external output will be set to off because Y100 is OFF Circuit is added to Refresh to the network module System B CPU module When M0 is set to ON in the System B CPU module Set Y100 external output to ON N Mo Mo Y100 100 J Mo Mo k iy iyoo m H He Refresh to the network module Y100 external output OFF ON OFF When a system switching occurs the output undergoes chattering ON Diagram 5 66 Operation When System S
332. fully 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 Hardware failure power OFF resetting or watchdog timer error occurring D1589 Disenabling on control system Condition Preparing for tracking communication Communication timeout Stop error on standby system except 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 Detecting network fault on standby system Initializes at 0 at same system power ON Stores 0 when system switching completes successfully ow oo NOUA The following bits are turned ON for each same system module from which a system switching request was issued Turns OFF on system after user has removed the corresponding module malfunction Each Bit Bits Same System b15to b11 to b1 b0 0 OFF sp1590 0 o 1 ae onl o EON Network Module a SD1590 No Issuing Module 0 Disabled because CPU O O Syst Switchi module is a 2 slot unit y Stem SW Iening Module 1 Module to the right of Request CPU module 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 OSet Not set
333. g 1 Device data Internal device refers to device set in the redundancy parameters tracking setting Section 5 5 3 Special relays and special registers refers to the automatically tracked special relay and special register Section 5 5 3 5 89 5 5 Tracking Function 5 5 6 Tracking Execution D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries 5 5 7 Tracking Mode Tracking mode determines processing when a new tracking request occurs before the ai previous tracking processing is completed i 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 z e Synchronous tracking mode z r e Asynchronous tracking mode mio 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 y a q S g Table5 52 Tracking Mode by Operation Mode and System Operating Status Operating Status Operation Mode Control Standby Backup Mode to Separate Mode to Backup Mode Separate Mode System System Separate Mode Backup Mode Synchronous Synchronous to asynchronized Asynchronous to synchronized fa x tracking mode 3 tracking mode tracking mode 2 Pa A woop RUN STOP eae PAUSE n z ota Stop Error l kadm RUN Asynchronous Asynchronous to asynchroni
334. g Serial Communication Module App 40 Appendix 6 2 UINI Instruction APPENDICES MELSEC Le eries 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 1 W O signal Table App 25 List of I O Signal VO signal R Pare Signal name Description CH1 side CH2 side Xn3 XnA Reception data read request ON Requesting read 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 Yn1 Yn8 Reception data read completion ON Data read completed 2 Buffer memory Table App 26 List of Buffer Memory Buffer memory address Hexadecimal decimal Stored value CH1 side CH2 side 2584 600 2684 616 Data reception result 1 or more Abnormal completion 0 Normal completion error code Receive data count 0 No receive data 6004 1536 A00 2560 Number of data for j 1 or later Number of receive data which read is requested 601 to 7FFy A01 to BFF 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 28 For the I O signal is X Y80 to X Y9F X83 X9F E 0 FROMP H8 H600
335. g points regarding writing data from the GOT and external device etc 1 The tracking data may not be reflected to the new control system CPU module depending on the timing of the system switching occurrence such as turning power supply OFF In this case data written immediately before switching systems by the GOT or external device may disappear Rewrite data after switching systems 7 4 Precautions at System Switching Occurrence PROGRAMMING CAUTIONS MELSEC TE eries 7 5 Precautions of Programming when Connecting Extension Base Unit OVERVIEW This section describes the precautions of programming when connecting the extension base unit 1 Precautions for using PX Developer As for the following functions use the dedicated instructions Do not use them to Ethernet module mounted to the extension base unit e Communication control FB SEND RECV e Event notification CONFIGURATION SYSTEM 2 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 L gt GX Developer Version 8 Operating Manual L gt PX Developer Version 1 Operating Manual Programming Tool TRACKING CABLE 3 Tracking device setting When tracking device setting is not set the program is executed using the value before refresh is
336. g to the Control System and Standby System When performing the online program change to the control system CPU module by GX Developer regardless of the connection route When the online program change is performed to the control system CPU module data will be written to the control system and standby system CPU modules Diagram 5 65 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 K aa S eSlzle ots Coll DCO Ts 1 Execute writing during i RUN to new control _ CPU module Write during system CPU module write to standby system CPU module program A running Program memory Program A Program memory Program A T _ _ INC Do Addition Y1A0 T s INC DoH nao Y1A0 H Honec D10 L Ap Diagram 5 65 Procedure for Writing to Control System and Standby System When Program Is Changed during CPU RUN 5 6 Online Program Change for Redundancy 5 100 5 6 2 Program Change While CPU is Running OVERVIEW CONFIGU
337. g to the standby system CPU complete lt GX Developer Diagram 5 85 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 Q12PRHCPU Q12PRHCPU MODE RUN ERR USER BAT BOOT MODE RUN ERR USER BAT BOOT JIN Flashing red Diagram 5 86 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 5 117 5 7 Memory Copy From Control System To Standby System D REDUNDANT SYSTEM FUNCTIONS aLS eG Q series 3 When 3D1H is stored in the special register SD1595 and the special relay SM1595 is turned ON the contents of control system memo
338. g torque 29 4 Necm e yo Connector Screws Flathead screwdriver Diagram 4 7 Fixing a Tracking Cable Connector 4 10 4 2 Wiring PROCEDURE FOR STARTING UP A REDUNDANT SLES M als 26 FY caries 4 Connecting extension cables When using the redundant type extension base unit connect extension cables by the following procedures g 3 System A connector System B connector Zz G zo Control system Standby system D z HO i z Tracking cable O z x O Extension cable Q65WRB A Q68RB IN1 IN2 OUT i Lu wn gt 2 p FA Ed m Zz a W a S 2 lt ws a2 Ok ES Lu D 1 z gt 1 n 5oy a Zr DOG az Zr Diagram 4 8 Connection method for extension cables when using the redundant type extension 2 base unit e Zn 1X om 22 a Connecting the main base unit to the redundant type extension base unit i Wy e System A extension cable Connect to IN connector IN1 on the redundant type extension base unit e System B extension cable Connect to IN connector IN2 on the redundant type extension base unit g 5 H o
339. gram 8 14 Flowchart for when SP UNIT LAY ERROR Occurs o zZ O O ol w l D 2 O hA 8 1 Troubleshooting Flow 8 26 8 1 13 When SP UNIT LAY ERROR Occurs 8 TROUBLESHOOTING 8 27 8 1 14 When LINK PARA ERROR Occurs M ELSEG seres The following shows the flowchart for when LINK PARA ERROR occurs during operation of the redundant system An error message LINK PARA ERROR was detected Are pairing settings made to the Redundant CPUs in the normal Recheck the pairing settings Is the number of modules set in network parameter same with the number of mounted modules Is the network number specified in network parameter same with the actual network number Is the start I O number set in network parameter same with the actual start I O Is the network type specified in network parameter same with the actual network type Check the network parameter and mounted status If they differ make them to the same Is the refresh parameter out of the range 8 1 Troubleshooting Flow 8 1 14 When LINK PARA ERROR Occurs TROUBLESHOOTING MELSEC TE eries NO Change the file register so that all the range can be refreshed Does the refresh range exceed the file register capacity OVERVIEW YES CC Link IE Controller Network module Is MELSECNET H module a relevant module
340. grams 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 OVERVIEW CONFIGURATION SYSTEM e Either control 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 TRACKING CABLE 2 Operating Status Consistency Check The operation status consistency check cannot be performed during online program change 3 Main base unit configuration The main base unit configuration check cannot be performed during online program change However if 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 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le 4 Parameter valid drive settings consistency check The parameter valid drive settings consistency check cannot
341. hange the tracking mode settings at the tracking settings in the redundant parameter settings a 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 Js 1 Error occurrence END fa Run END CPU module program 1 ie d e 2 _ es New Standby system a tT Non executed CPU module Send Send Tracking processing 1 Tracking processing 2 Receive Receive Standby system 5 5 CPU module 0 Run program in T kag a 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 52 Synchronized Tracking Mode Operation Timing 5 91 5 5 Tracking Function 5 5 7 Tracking Mode D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries b Program Priority Mode In program priority mode the control system CPU module executes the scan execution type program as soon as tra
342. he CPU module uses the parameters for system A to operate Therefore the station set as system B in the network parameters becomes absent station disconnected station 4 System Startup Order No restrictions apply to the startup order of system A and system B when connected to the Ethernet 6 29 6 2 Redundant System Network Overview 6 2 3 Ethernet REDUNDANT SYSTEM NETWORKS MELSEC TE eries 6 2 4 CC Link A redundant system can continue the CC Link control by CC Link standby master ai function even when system switching occurs i O When using this function set the system A as master station that controls the data link and system B as standby master station for backup of master station Refer to the following manual for CC Link standby master function lt CC Link System Master Local Module User s Manual a Master Station Standby Station 3 Station No 0 Station No 1 m g
343. he 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 execution Takes over the current setting 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 Turns on continues Turns off continues Turns on flickers and then turns off 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 execution 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 Cont
344. he function Executes the function Executes the function Executes refresh from network module to CPU Does not execute the module Does not execute the function Does not execute refresh from CPU module to function network module Executes the function 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 Base not execute me Executes the function Doesinot oxecutg ne function function 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 STOP 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 72 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu E n gt N i Z lt S Zz a Lu ao o Z O O Z Le REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS Ml ELSEG Q series 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 system
345. he 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 24 5 1 4 System Consistency Check OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series 6 Parameter Valid Drive Settings Consistency Check 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 system Standby system COl 1CO am CACA
346. he remote station output holding time output holding time at system switching occurrence Table6 5 Remote Station Output Holding Time Reasons for System Switching Output Holding Time Calculation Expression ms Control system power off When 3 x LS gt 100ms Control system CPU module reset Output holding time error detection processing time 1 100 6 x LS SS I O Control system CPU module stop error response time When 100ms gt 3 x LS Control system CPU module hardware fault Output holding time error detection processing time 1 200 3 x LS SS I O response time System switching by GX Developer When 3 x LS gt 100ms Output holding time error detection processing time 1 300 6 x LS 2 x SS I O response time When 100ms gt 3 x LS Output holding time error detection processing time 1 400 3 x LS 2 x SS I O response time REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM FUNCTIONS ez System switching by system switching instruction System switching by system switching request from network module W wn gt n j A Ed a Zz fa W a n X x e z E W zZ LS Link scan time Refer to the following manual for the link scan time calculation method L gt CC Link Master Local Module User s Manual Details SS Sequence program scan time 1 Use the value in Table6 6 as the error detection proce
347. hen 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 FUNCTIONS Table7 5 Reasons for 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 No Reasons for System switching REDUNDANT SYSTEM NETWORKS e Control system CPU module reset executed without tracking the bas e Control system hardware fault output may change at the time e Control system CPU module stop error of system switching e System switching request from network module Since system switching is done 2 System switching instruction execution after tracking the output does e System switching request from GX Developer or OPS not change at system switching 1 z o a g OF o3 ect ao 2 Not selectable since an intelligent function module cannot be
348. hen 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 POINT When starting up a single basic system use the debug mode Refer to Section 5 1 3 for the debug mode TRACKING CABLE PROCEDURE FOR STARTING UP REDUNDANT SYS NETWORKS 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 PROGRAMMING CAUTIONS Table5 2 Confirming SM1511 and SM1512 to Identify System A and System B SM15114 SM1512 System A ON OFF 5 1 Basic Concept of Redundant System 5 1 1 Determination of System A System B a 6 TROUBLESHOOTING Section title The section of the open page is shown at a glance 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
349. hing 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 CC Link IE Controller Network or MELSECNET H PLC to PLC network 6 11 6 2 Redundant System Network Overview 6 2 1 CC Link IE Controller Network or MELSECNET H PLC to PLC network REDUNDANT SYSTEM NETWORKS MELSEC TE eries Example Diagram 6 9 shows the redundant system operation when the control system network module detects a communication error on the assumption that the control system network module is the control station of station No 1 and the standby system network module is the normal station of station No 2 Normal station Normal station Station N
350. his 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 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM system This function copies program memory contents from the control system to the ol 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 Allows replacement of an I O module mounted on the main base unit where Lu wn gt wn Zz a a Zz fa W a o Z O O Z Le the Redundant CPU is mounted while power supply is ON Not applicable when any extension base unit is connected e Allows replacement of an I O module or intelligent function module a Online Module Change A mounted on an extension base unit while power supply is ON Section 5 8 Hot swapping Allows replacement of an I O module or intelligent function module k mounted on a MELSECNET H remote I O station while power supply is ON REDUNDANT SYSTEM NETWORKS Allows replacement of a power supply module while the system is operating when the system uses the redundant power main base unit 1 I
351. host registers SW SB49 Data link status of host gt Q Corresponding MELSECNET H SW70 9 Baton pass status of each station 10th station Network System Reference Manual SW74 9 Data link status of each station 10th station Remote I O Network Standby system to control system switching SM1518 poe status flag M200 Read request flag M201 REMER instruction execution flag M202 System switching triggered REMFR instruction Change the device number according to the re request flag system M203 REMER instruction completed flag M204 REMER instruction abnormally completed flag 2 The complete signal is not tracked even it is set for tracking 7 2 7 1 Instructions Restricted in Use for Redundant System PROGRAMMING CAUTIONS MELSEC TE cries 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 SM1518 M201 E _ Turns ON M202 when system i 0 i SET M202 jj switching occurs during execution 0 of the REMFR instruction SM1518 SB20 SB47 SB48 SB49 SW70 9 SW74 9 M203 M200 M201 E 7 3 44 H 4 4 it t t SET M201 Turns ON M201 to execute the REMEFR instruction when M200 or M202 7 M202 is ON the MELSECNET H KO gt remote I O network is normal and 2 normal communication can be T r made with the remote I O station o Ko gt Z REMFR j4
352. i Sars Details aaa Confirmation of dedicated instructions for PID control Details TRACKING CABLE eae Confirmation of dedicated instructions for process control Details Confirmation of MELSAP3 s system configuration A performance specifications Details functions programming debugging and error codes Confirmation of the programming method specifications functions etc Details required for SFC programming of the MELSAP L type REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A lt lt lt REDUNDANT SYSTEM FUNCTIONS Confirmation of the programming method of the Details structured text language REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 1 OVERVIEW MELSEC TE cries 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 of both systems with a tracking cable I O module s and intelligent function module s are installed to MELSECNET H remote I O station s or ext
353. iagram 8 10 Flowchart for when EXT CABLE ERR occurs 1 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 8 21 8 1 Troubleshooting Flow 8 1 9 When ETX CABLE ERR Occurs 8 TROUBLESHOOTING M ELS 2G Kel series 8 1 10 When BASE LAY ERROR Occurs The following shows the flowchart for when BASE LAY ERROR occurs during operation ai of the redundant system i 5 Error message BASE LAY ERROR was detected 9 g Does the number of Ch th ber of st f ext D Is error code 2010 Stages of extension base unit exceed EA al Sanai pe e z specifications a 2S nO Check serial No of CPU module by i system monitor of GX Developer a S o zZ x O Is first 5 digits of serial Replace CPU module with the one No of CPU module 09012 compatible with extension base unit or later a x lt 3 woe agg Hardware failure of the following modules WEZ is suspected 9 c a Extension base unit a eExtension cable Consult your local Mitsubishi representative explaining a detailed description of the problem a 2 wn zn 56 ZE DOG az rare W D gt wn Zg aon zo Be W Ww eZ o o 56 z2 ao o e o zZ O O ol w l D 2 O hA 8 1 Troubleshooting Flow 8 22 8 1 10 When BASE LAY ERROR Occurs
354. ialog box will appear 1 L Cannot execute this function when the PLC is not control system lt Memory copy executed in Debug Mode 424Dx will be stored in SD1596 of the control system CPU Memory copy re executed during memory copy During online program change or similar operation to the control system CPU module i The memory copy Function is being executed J Please execute it again for a while after time lt ES 010a4247 gt The following error dialog box will appear E MELSOFT application JD Please execute it again after it completed online change Function lt ES 010a424c gt This peripheral device or another peripheral device are operating online change function 4247 will be stored in SD1596 of the control system CPU 424C will be stored in SD1596 of the control system CPU Memory copy target I O No SD1595 is any value other than 3D1H 4248 will be stored in SD1596 of the control system CPU Standby system power OFF Standby system CPU module reset Tracking cable disconnection 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 HW problem lt E5 010a4241 gt E MELSOFT application i The tracking cable has a communication problem J Please ex
355. ication system status check TRK INIT ERROR 6140 a 6 Extension base unit mounting check BASE LAY ERROR 2010 to 2013 9 7 For unsupported module being mounted check SP UNIT VER ERR 2151 G 8 Main base unit bus check Cee 1411 9 Extension base unit bus check f 1418 10 Extension base unit mounting status EXT CABLE ERR 2020 11 Base assignment check SP UNIT LAY ERR 2122 2125 a 12 Booting check BOOT ERROR 2210 2211 5g 13 For parameters check MISSING PARA 2200 ws 2100 2103 a26 14 Parameters and system configuration check SP UNIT LAY ERR 2106 2107 S a 2124 2125 2128 lt i 15 Intelligent Function Module check SP UNIT DOWN 3 1401 1403 5 16 RUN STOP switch status check OPE MODE DIFF 6020 Control system and standby system configuration z 17 UNIT LAY DIFF 6030 2 check Eo 18 Redundant System Control system and standby system CPU module UNIT LAY DIFF 6035 56 Startup Ability MOIES Cg a2 For control system and standby system memory card care 19 Check CARD TYPE DIFF 6040 6041 settings check 3000 to 3004 20 Parameter settings check PARAMETER EEROR 3007 3040 fi 3041 3042 gt ao File storage to program memory check FILE SET ERROR 2400 2401 zy 22 Program files check CAN T EXE PRG 2500 to 2504 z 23 Instruction codes check INSTRCT CODE ERR 4000 to 4004 D m 24 Pointer P check CAN T SET P 4020 4021 25 Pointer 1 check CAN T SET I 4030 26 END instruction check MISSING END INS 4010 27 Link parameter error LINK PARA ERROR 31
356. ide of the power supply module mounted on the main base unit CPU slot ge shes F 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 22 1 OVERVIEW MELSEC TE eries 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 6 1 Specifications and handling of QCPUs Power Supply Modules Base 5 Units memory Cards etc o eE L gt QCPU User s Manual Hardware Design Maintenance and Inspection 26 2 Common Functions Programs and Devices for QCPUs L gt QCPU User s Manual Function Explanation Program Fundamentals g 5 FE a woe HEE Or 5 o ZE az ard ai D a ZO Be aed z o E 2 4 i 3 fe OVERVIEW 3 List of Redundant CPU manuals Redundant CPU manuals are shown below For details such as manual numbers refer to ABOUT MANUALS in this manual Purpose Confirmation of part names and specifications of the CPU module Table1 1 List of user s manual of redundant CPU Maintenance and Inspection QCPU User s Manual Hardware Design Maintenance and inspection Details Na Q Program Fundamentals Multi CPU System QCP
357. ils on the CPU module LED lt gt QCPU User s Manual Hardware Design Maintenance and Inspection 7 The control system and standby system can be identified by checking whether the special relays Control Standby Status flag SM1515 and Control Standby Status flag SM1516 are ON or OFF Table5 4 Confirming SM1515 and SM1516 to Identify Control system and Standby system Control system ON OFF Standby system OFF ON 5 7 5 1 Basic Concept of Redundant System 5 1 2 Determination of Control System and Standby System D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries 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 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 1 Basic Concept of Redundant System 5 8 5 1 2 Determination of Control System and Standby
358. in in the separate gt mode Failure to do so may cause the TRK CABLE ERR error code 6120 z9 ao stop error in the CPU module of that system 29 Q rz 2 o E 2 5 O i 3 e 5 1 Basic Concept of Redundant System 5 12 5 1 3 Operation Mode D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series 3 Debug Mode The debug mode is for debugging with a system configuration of only either system prior to the system operation In a redundant system two Redundant CPUs are normally required however debugging can be executed with only one CPU An error will not occur even if the tracking cable is not connected In the debug mode the CPU module is fixed to system A and control system and uses the parameters for system A to operate Therefore the station set as system B in the network parameters becomes absent station disconnected station Confirm that the redundant system is running in the debug mode by checking the relevant LEDs of the CPU module Table5 7 Checking the BACKUP LED to Confirm the Debug Mode CPU module LED LED Status Q12PRHCPU LED Name LED Status MODE BACKUP wA g BACKUP SYSTEMA Sp Set CONTROL BAT oo SYSTEMA SYSTEME Refer to the following manual for details on the CPU module LED lt gt gt QCPU User s Manual Hardware Design Maintenance and Inspecti
359. 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 Microsoft Windows Windows NT and Windows Vista are registered trademarks of Microsoft Corporation in the United States and other countries Pentium is a trademark of Intel Corporation in the United States and other countries Ethernet is a trademark of Xerox Corporation All other company names and product names used in this manual are trademarks or registered trademarks of their respective companies SH NA 080486ENG O QnPRHCPU MODEL QNPRHCPU U NI E
360. ing Diagram 5 78 Redundant Operation Screen Showing w Normal Completion Abnormal Completion D S o zZ x 2 Memory Copy from Control System to Standby System Using GX g Developer 7 The following provides the procedure for executing memory copy function using GX Developer and the relevant operations xh Oa gt a Procedure Te RE 1 Connect the control system and standby system CPU modules with a tracking 29 Or cable and power on the standby system in Control system CPU module ol Q12PRHCPU Q12PRHCPU MODE RUN ERR USER BAT BOOT MODE RUN ERR E USER BAT BOOT BACKUP CONTROL SYSTEMA SYSTEMB riy Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le Flashing red Diagram 5 79 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 fi wn gt N 2 Connect GX Developer to the control system CPU module zy Identify the control system CPU module on the CONTROL LED or with the 28 special relay SM1515 Control Status ON SM1516 Standby status OFF i Wy S o 56 z2 ao 2 5 Q A a 5 7 Memory Copy Fro
361. ing blocks for tracking settings X3 F1 x K9 F2 x K10 F3 x K11 ms Z Number of Program Steps D1 to D4 E1 to E4 F1 to F3 and K1 to K11 are values used in Table9 6 9 7 9 2 System Switching Time Q PROCESSING TIME FOR REDUNDANT SYSTEMS M eLS eG lA cries 9 Table9 6 Counting Value of D1 to D4 E1 to E4 F1 to F3 and K1 to K11 25 lt System A z z Counting Hog Content Number O x m Value Oxy Symbol mane D1 Number of Tracking Device Points outside of Index Register K1 0 09 x 10 73 D2 Number of Tracking Device Points for Index Register K2 0 15x 103 Number of Tracking Device Points for Standard RAM File D3 K3 0 09 x 10 Register 2 Number of Tracking Device Points for SRAM Card File 5 D4 K4 0 42 x 10 A Register Q lt E1 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 h K7 5x103 Register Number of Tracking Device Ranges for SRAM Card File E4 K8 5x103 Register is F1 Number of Blocks not Including File Register K9 1x103 F2 Number of Blocks Including Standard RAM File Register K10 25x 10 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 digits of serial No is 06081 or before 120 3 x G3 x 103 QnPRHCPU whose first
362. ing cable MELSECNET H Remote I O network m g 6 Fa aa mal fH I Eie e IH ES ee ME 71 a ii l E Remote O station Remote I O station Reg station No 2 station No 3 ube aot RE o Multiplexed Remote Master St Multiplexed Remote Sub master Master Station station No 0 oP Station station No 1 station Control _ Standby Standby _ Control u system System system System L a zi N al f HE a E Zy a e a a e qZ 1 Stop Error has 7 el faye occurred 2 Perform system switching g 5 5 aie a 4 2 5HE g5 a H i i rad Tracking cable ez MELSECNET H Remote I O network W wn gt n H A lt x a Zz a W ao n X x e z E W zZ Remote I O station Output is preserved Remote I O station Output is preserved station No 2 during system switching station No 3 during system switching g Diagram 6 14 Redundant System Operation at System Switching 7 22 6 E rar ao o zZ 0 T n w l a gt O o 6 2 Redundant System Network Overview 6 18 6 2 2 MELSECNET H Remote I O network 6 REDUNDANT SYSTEM NETWORKS M ELSEG Q series 3 Redundant System Operat
363. ing parameters and programs to CPUssesses9e4 14 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 product
364. 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 C 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 function version D or later b GX Developer version Use 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 G230771 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 C gt PROFIBUS DP Master Module User s Manual 6 43 6 2 Redundant System Network Overview 6 2 6 PROFIBUS DP 6 REDUNDANT SYSTEM NETWORKS M als 26 Kel series
365. inues 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 eG Q series 5 4 Operation Mode Change Function 5 64 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series Table5 41 Operations When Changing Operation Mode Continue F Backup Mode to Separate Mode Function Standby system SS Device memory Continues execution SM SD t ntem Stops tracking dependent Data tracking SFC information Stops tracking L3 Section 5 5 3 PID control instruction Slope racking information Redundant Si 3 A gnal flow with tracking function ATA Stops tracking Consistency check between System A amp B e There are no items to be checked when operation mode change is made Section 5 1 4 Stops operation status consistency check
366. ion In these cases the error dialog box in Diagram 5 60 will appear on GX Developer Mi 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 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 Tracking cable connection or disconnection If any of the above operations is performed Consistency check between system A and B may cause the FILE DIFF error code 6000 stop error in the standby system CPU module In addition the error dialog box in Diagram 5 61 will also appear on the GX Developer that performed the PC write E 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 61 Error Dialog Box Displayed on GX Developer If the error dialog box Diagram 5 61 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 detail
367. ion Error in Network other than CC Link When a communication 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 MELSECNET H PLC to PLC network Station number used for the network o networ a Master Station Station No 0 Standby Station Station No 1 System A Control System e System B Standby tS ooo000 ooo O coo L Tracking cable CC Link Remote I O station station No 2 MELSECNETIHT PLC to PLE network Station number used for the network O networ oe he Maste
368. ion condition is satisfied before the systems are switched b Relevant Instructions e LDP ANDP ORP e MEP e PLS GP Examples MOVP INCP etc SP C GP 9 ZP 7 JP Intelligent Function Module Dedicated Instructions FF LEDR DUTY TRACE TRACER Fall Instruction If signal flow memory has not been tracked after system switching the fall instruction is processed as explained below a Processing When the systems are switched the new control system CPU module turns on data in the signal flow memory For this reason the CPU module executes the fall instruction again if the fall instruction execution condition is turned off before the systems are switched b Relevant Instructions LDF ANDF ORF e MEF e PLF 7 1 Instructions Restricted in Use for Redundant System PROGRAMMING CAUTIONS M eLS 26 Fel series 4 SCJ Instruction Note that jump processing for the specified pointer P varies with whether tracking signal flow memory has been tracked or not if the SCJ instruction contact turns ON 5 5 2 gt during system switching processing a When signal flow memory has not been tracked Jumping is executed from the first scan after system switching r O b When signal flow memory has been tracked 5 Jumping is executed from the second scan or later after system switching o SZ n zZ When Signal flow memory is not tracking ao
369. ion 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 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM ol In the backup mode 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 m E v gt a z lt fa zZ 5 fal w ind 2 Z O E O Z 5 Le REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 5 1 Basic Concept of Redundant System 5 10 5 1 3 Operation Mode D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series 2 Separate Mode The separate mode is for maintenance without stopping control In the separate mode different programs can be run in the control system and standby system CPU modules While continuing the system control in the control system program of standby system can be corrected and operation of program can be checked by using the data tracked from the control system a Enabling Disabling the Tracking Function In the separate mode it is possible to select
370. ion when a Communication Error Occurs in the MELSECNET H Remote I O Network a System Switching Procedure 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 1 When a communication error occurs in the MELSECNET H remote I O network the control system network module issues a system switching request to the control system CPU module 2 When receiving the system switching request from the network module the control system CPU module performs END processing Through the processing system switching is performed 3 After system switching is completed the new control system network module continues the data link 6 19 6 2 Redundant System Network Overview 6 2 2 MELSECNET H Remote I O network REDUNDANT SYSTEM NETWORKS MELSEC KE eries 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 OVERVIEW Multiplexed Remote Sub master Multiplexed Remote Master Station station No 1 Station station No 0 CONFIGURATION SYSTEM Control system Standby
371. ircuit 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 Supply power to two redundant power supply modules individually redundant power supply module 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 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 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 SLES M als 26 FY caries 2 Connecting the Q6BAT Battery Connectors The CPU module Q6BAT batteries are shipped with the battery connectors disconnected Connect the battery connectors according to the following procedure prior to use OVERVIEW a Confirming Battery Installation Status Open the CPU module bottom c
372. iring settings check the GX Developer version L37 Section 2 3 2 The Q4ARCPU makes pairing settings using the J PAIRSET instruction 3 The pairing settings cannot be made with the Q4ARCPU in the CC Link IE Controller Network 2 6 2 1 System Configuration 2 SYSTEM CONFIGURATION MELSEC TE eries 4 Communication via MELSECNET H Remote I O Network a Controlling External Devices A redundant system controls external devices using I O modules and intelligent function modules that are installed to remote I O stations on the MELSECNET H remote I O network Communications with external devices are also available by installing a communication module to a remote I O station when it cannot be mounted on the main base unit of the redundant system OVERVIEW N z O T 5 o Le Z Q SYSTEM b Backup of Power Supply Module The power supply module for each remote I O station can be backed up By adding a backup power supply module to a remote I O station the remote I O station can continue to operate even if an error occurs in either 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
373. is explained here The time required for system switching will also be explained Q PROCESSING TIME FOR REDUNDANT SYSTEMS M als 26 Fel ceries 9 1 Extension of Scan Time due to Tracking Refer to Table9 1 for the calculation of extended scan time of control system CPU module due to tracking Sk z Fq ova 22 8a w Ww or 28 on an Lu n gt N Table9 1 Extension of Scam Time due to Tracking Tracking Mode Scan Time Extension Time ms Extension of Scam Time n END S Sequence Tra e Sequence a Control system l a F s l lt Synchronized Tracking LL Ts Tra Trb Mode Fe Tracking transfer process Standby system l Adjust Tracking transfer data X lt f Extension of Scam Time 2 Sequence Tra J0 Sequence Tra jo Control system Trb Tp gt Trb Ts Trat g Tracking transfer process Standby system l Prog ram Adjust Tracking transfer data Priority Extension of Scam Time Mode END Sequence Tra jo h _ Z e Control system Pa Sequence Trb Tp lt Trb Ts Tra Trb Tp Tracking transfer process Standby system Adjust Tracking transfer data Ts Scan Time Extension Time Tra Tracking Data Preparation Time Both systems are normal i i j Momentary power Trb Tracking Processing Time When a momentary power failure or yP failure time to max 40 a Overhead time fo
374. itions is executed even during cas SM1709 enable setting during online online program change redundant tracking regardless of the status of this relay program change redundant Power off reset hardware failure CPU stop error tracking 3 In either of the following statuses the system switching disable status can also be canceled by this relay z e Multiple block online program change redundant tracking execution status e File batch online program change redundant tracking execution status Z e Online file writing redundant tracking execution status z 1 Set whether the tracking of the following data will be executed or not during online program change redundant tracking e Device memory S Including SM SD that will automatically execute tracking Ye B Transfer tracking data during i oes PID control command information SFC information Lite SM1710 online program change enable res m S 5 fag 2 Thi relay can be alee used to set whether tracking is t be executed or nor in the z 9 lt multiple block online program change or online file writing redundant tracking 5 BS execution status D 3 This SM is also transferred form control system CPU module to standby system CPU module by tracking data 5 b Special Registers For Online Program Change 7 Special registers for online program change are shownin Table5 56 E az Table5 56 Special Registers For Online Program Change 5 z Number Name Explanation care 1 Seti
375. k IE Controller Network Reference Manual 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 1 16 When CAN T SWITCH Occurs to Control System CPU Module due to Communication Error when 8 TROUBLESHOOTING MELSEC TE eries 8 2 Error Clear z In a redundant system the errors that continue the CPU module operation can be cleared gt The following methods for error clear are available in a redundant system e Clearing the host CPU module error e 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 E connected to the control system CPU module Ba O nO 1 Clearing Host CPU Module Error The host CPU module error can be cleared using a special relay SM50 and a special register SD50 M q a Procedure 9 Error clear is performed according to the following procedure 1 Remove the cause of target error E 2 Store the corresponding error code into a special register SD50 3 Turn special relay SM50 from OFF to ON 7 z Oa 4 The target error is cleared ae 204 If the error is cleared and the CPU module returns to normal the relevant special R28 relay special register and LED return to the previous statuses paca If the same error occurs again after that it will be re
376. l I O forced ON OFF registration cannot be executed individually for the control system and standby system CPU modules TROUBLESHOOTING 5 10 Redundant CPU Functions Restricted in Redundant System 5 128 5 10 1 Enforced ON OFF of external I O D REDUNDANT SYSTEM FUNCTIONS Item Input MELSEC TA eries 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 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 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 mounted on remote I O station Device X remains ON OFF according to the forced ON OFF information Item Input 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
377. le zo ao Ze D100 1234 AZ D101 2345 wit Diagram 5 19 Hot Start Mode Operation Lu D gt N Ze ou ZO ae W Lu ez o o 56 ao 0 zZ o O 35 if a z 5 1 Basic Concept of Redundant System 5 30 z 5 1 6 Start Mode D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q 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 All Other Than Index Register Not held in power OFF Cleared Held 1 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 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 gt 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
378. le For details refer to the following manual C gt GOT1000 Series Connection Manual Mitsubishi Products 6 47 6 3 Communication between the Both Systems CPU Module and GOTs 6 3 1 When connecting GOTs to MELSECNET H remote I O station 6 REDUNDANT SYSTEM NETWORKS M als 26 fel ceries 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 ai extension base unit or connect it to the CC Link communication module AJ65BT G4 S3 i connected to the CC Link 2 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 station Control system Standby system 5 fz E z i en i ae a Bl ay i oie nz H gt Bl f ao g gima alla 2 5 x 02 8H E 5 2 g l a H g 3 3 al EIE E Tracking cable CC Link u a Ll GOT1000 Series GOT1000 Series 5 GOT A900 Series AJ65BT G4 S3 GOT A900 Series S ES O fe GOT1000 Series GOT A900 Series Remote device station Intelligent device station
379. le en O O I O combined module ot O O Analog input module C x C O Analog output module C x O O Temperature input module C x O O Temperature adjustment module C x O O Pulse input module C x O O 2 22 7 1 When the extension base unit is connected online module change hot swapping cannot be performed to modules mounted on the main base unit O Online Module Change Hot Swapping Possible x Online Module Change Hot Swapping not Possible because cannot be mounted on a main base unit Refer to the following manuals for online module change hot swapping of input modules output modules and I O combined modules a Main base unit where Redundant CPU is mounted C gt QCPU User s Manual Hardware Design Maintenance and Inspection b Extension base unit L gt Q Corresponding MELSECNET H Network System Reference Manual Remote I O network Refer to the manual of each module for online module change hot swapping of analog input module analog output module temperature adjustment module and pulse input module 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 L gt Q Corresponding MELSECNET H Network System Reference Manual Remote I O network 2 4 System Configuration Cautions 3 TRACKING CABLE M eLS eG cries This ch
380. le 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 Turning ON power supply of standby system REDUNDANT SYSTEM FUNCTIONS Check that RUN STOP switch of the standby system CPU module is set to RUN STOP 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 Checking POWER LED of the power supply module REDUNDANT SYSTEM NETWORKS Check that POWER LED of the power supply module is turned ON green and power supply is supplied normally Start standby system Diagram 8 37 Replacement Procedures of Extension Cable PROGRAMMING CAUTIONS o e o zZ O O ol w l D 2 O hA 8 3 Replacing Module in Redundant System 8 52 8 3 10 Replacement Procedures of Extension Cable Q PROCESSING TIME FOR REDUNDANT SYSTEMS MELSEC TA eries CHAPTER9Y PROCESSING TIME FOR REDUNDANT SYSTEMS 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 User s Manual Function Explanation and Program Fundamentals The method for adding tracking time
381. lt lt First 5 digits of serial 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 System Configuration 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 App 9 Appendix 3 Comparison of QNPHCPU and QnPRHCPU APPENDICES MELSEC TE eries Table App 6 Comparison of QnNPHCPU and QnPRHCPU Continued Item QnPRHCPU QnPHCPU lt lt First 5 digits of serial No is 09011 or earlier gt gt N A Modules for the expanded system are mounted to MELSECNET H remote I O station Restrictions on Mounting Modules on Remote I O Stations e FROM TO instructions and intelligent function PROCESSING TIME FOR REDUNDANT SYSTEMS module devices U _ G _ are inapplicable Use REMFR REMTO for accessing Or in GX Configurator configure the settings for intelligent 1 APPENDICES function modules on remote I O stations e The following modules cannot be mounted to remote I O stations CC Link IE Controller Network module MELSECNET H module interrupt module Web server module MES interface module PROFI
382. m 8 3 6 Main Base Unit Replacement Procedure 8 TROUBLESHOOTING M ELS 26 Fel ceries 2 Replacement Procedure The replacement procedure for the main base unit is indicated in Diagram 8 34 Confirm that the main base unit to be replaced is for the standby system CONTROL LED is a off When replacing the control system s power supply module switch it to be the standby system 2 using GX Developer s system switching g Refer to Section 5 2 regarding system switching via GX Developer z 58 F 1 Disconnect the tracking cable from the standby system CPU module lt Refer to Section 3 3 for disconnecting the tracking cable S 2 Disconnect the power supply cable from the standby system power supply module 3 Disconnect the network cable from the network module E Refer to the manual of the network module for disconnecting the network cable 4 Remove the connector terminal block from the I O module 5 Disconnect the extension cable for mounting the main base unit of the standby system 3 E P lt woe 598 Remove the modules from the main base unit 8 7 5 Refer to the QCPU User s Manual Hardware Design Maintenance and Inspection for A removing modules l 2 Mount an alternative main base unit to the control panel etc 2 ZE ag pa 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 th
383. m B identification flags before and after write of device data ee en 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 device 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 Change the connection setup NO Inconsistent System switching occurred Can the data be read normally YES Communication normal Are the SM1511 and SM1512 contents read in 1 and 3 consistent YES Consistent End Diagram 6 42 Flowchart for Checking for System Switching with the system A and system B identification Flags 6 55 6 5 Precautions for Writing Device Data from Other Station PROGRAMMING CAUTIONS M eLS 26 Cel series wu This chapter provides the programming cautions restrictions on instructions and fixed scan clocks and fixed scan execution type programs 5 7 1 Instructions Restricted in Use for Redundant System Some instructions are restricted in use to a redundant system as indicated below z z9 A aie A PS 1 Instructions Requiring a Certain Number of Scans 28 a Instruction Operations Some instructions require a certain nu
384. m CPU module develops ina 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 47 8 3 Replacing Module in Redundant System 8 3 6 Main Base Unit Replacement Procedure 8 TROUBLESHOOTING M eLS 26 Fel ceries 8 3 7 Procedure for Replacing Module mounted on the I O Station of Redundant System a gt By using the online module change of GX Developer the module mounted on the i 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 1 Intelligent Function Module 2 5 Analog module temperature input module temperature control module pulse be input module oe 1 Refer to the following manual for module replacement by using online module change of GX Developer ae Q Corresponding MELSECNET H Network System Reference Manual z Remote I O network z 2 Refer to the manual of the intelligent function module for module replacement by using online Z module change of GX Developer lt E POINT Intelligent function modules other than the above cannot be replaced online using fi GX Developer Bak When replacing these intelligent function modules power off the remote I O Boe station in advance eZ 5 2E
385. m Control System To Standby System 5 114 D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series 3 Select Memory copy on the Redundant operation screen of the Online dialog box on GX Developer and click the Execute button Redundant operation Connection target information Connection interface COM1 lt gt PLC module Target PLC Station no Host PLC type Q25PRH PLC status RUN System type Control system Operation mode Backup mode Remote operation Memory copy progress status System switching Memory copy progress is displayed in Change operation mode EI Select Memory copy Diagram 5 80 Redundant Operation Screen 4 When the memory copy confirmation dialog box appears click the Yes button This transfers the control system data to the standby system MELSOFT series GX Developer t Execute e Diagram 5 81 Confirmation Dialog Box Displayed on GX Developer Then the BACKUP LED of the standby system CPU module will flash red Control system CPU module Standby system CPU module U Flashing red Q12PRHCPU Q12PRHCPU ord MODE BACKUP Gl MODE O BACKUP E RUN CONTROL RUN CONTROL ERR al SYSTEMA ERR lt SYSTEMA USER SYSTEMB ON red USER SYSTEMB BAT BAT BOOT BooT C ON red Fla
386. m Standby System p W ia mm g s 30 8 Hp amp 82H g 3 a e a B 8 CH Input Output Input Output igital a a le C put Outpu nput Outpu Digital Analog unit unit Converter Unit Tracking cable CC Link Remote I O Remote I O Remote Device App 13 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 the program name should also be changed in the program settings of the PLC parameter settings Table App 9 Sample Program Names Execution g Program Name Processing Content Type A processing program that makes QJ61BT11N usable with redundant system CPUs CHANGE Scan 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 Appendix 4 1 Sample Program System Configuration APPENDICES MELSEC KE eries Appendix 4 3 Devices Used in Programs 1 CPU Module Devices Device Nos used in sample programs and their applications are shown in Table App 10 and Table App 11 PROCESSING TIME FOR REDUNDANT SYSTEMS Table App 10 CPU Module Devices Device Number Application Remarks SM400 Always On o 8 SM
387. m switching is complete the new control system CPU module starts all fixed scan clocks from OFF Therefore the OFF time is extended T t as shown in Diagram 7 6 The maximum value of the extension time when t t is T t CONFIGURATION SYSTEM Control system New standby system System switching activated Control system Ys s ese i Fixed Cycle Clock SM409 to SM415 New standby system TRACKING CABLE Standby system Begin system switching Ne System Switching complete Fixed Cycle Clock SM409 to SM415 Newcontrolsystem ss ee Extension of Off time REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A t t Standby system New control system t x fixed cycle interval T System switching time period between start of fixed cycle clock OFF and beginning of system switching 0 lt t lt t REDUNDANT SYSTEM FUNCTIONS Diagram 7 6 Operations of Fixed scan Clocks at System Switching 2 Fixed scan Clocks SM420 to SM424 When system switching is complete SM420 to SM424 remain OFF in the new control system CPU module Execute the DUTY instruction in the new control system CPU module to make SM420 to SM424 usable in the new control system CPU module REDUNDANT SYSTEM NETWORKS bas 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 A SM1518 Perform DUTY 22
388. mber of scans from start to completion of the execution If system switching conditions are satisfied while this kind of w a instruction is being executed the CPU stops the execution and the relevant S o processings will not be completed In this case it is necessary to use the user program to execute that instruction again after system switching Table7 1 Instructions Requiring a Certain Number of Scans Lu Sat Instruction Execution 5 Instruction Classification i i TIo Symbol Completion Signal g z z Data processing SORT aes Sort Present Qua Instructions e DSORT eam Character String Read COMRD Present Processing Other Convenient Write data to specified file SP FWRITE Present fi Instructions Read data to specified file SP FREAD Present A m Instructions Dedicated to Intelligent Function Modules Present 42 2E 1 Refer to the manual of the intelligent function module used for the instructions dedicated to AZ intelligent function modules caine ai D ZO Be rz z o a g OF o3 E ao TROUBLESHOOTING 7 1 Instructions Restricted in Use for Redundant System T 1 PROGRAMMING CAUTIONS MELSEC Kel series b Countermeasures 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 switching 7 However note that the same instruction might be executed twice Example In the following
389. me 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 central position reset switch neutral position l Start standby system Diagram 8 21 CPU Module Replacement Procedure EJPOINT MELSEC TE eries 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 MELSEC KE eries 8 3 2 Power Supply Module Replacement Procedure 1 Power Supply Module Replacement The control system power supply module cannot be replaced while redundant 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 OVERVIEW Power supply module Control Standby system system a Fj l SS c CONFIGURATION SYSTEM
390. ment detailed setting of the PLC g parameter dialog box 5 Refer to the following manual for details of the I O assignment detailed setting 2 N L gt QCPU User s Manual Function Explanation Program Fundamentals 5 3 oO fe 6 2 Redundant System Network Overview 6 24 6 2 2 MELSECNET H Remote I O network 6 REDUNDANT SYSTEM NETWORKS M ELSEG Q series 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 i i Data link operation of i error occurrence Redundant CPU Output operation from remote MELSECNET H remote I O Redundant Remote I O control status I O station network CPU station Stop Depends on the output mode Stops control A 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 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 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 lt 3 QCPU User
391. module Input module Input module Output module Output module Output module Output module Power supply module Power supply module Q65B Q68RB Q64RP Q64RP Input module Input module Input module Output module Output module a Input module Input module Input module Output module Input module Output module Power supply module Diagram 2 6 MELSECNET H Remote I O Network Configuration d Reference Manual Refer to the following manual for modules that can be mounted on a remote I O station and parameter settings L gt Q Corresponding MELSECNET H Network System Reference Manual Remote I O network 2 1 System Configuration 2 SYSTEM CONFIGURATION MELSEC KE eries 5 Communication via CC Link a Controlling External Devices A redundant system controls external devices using remote I O stations remote device stations and intelligent device stations connected to CC Link OVERVIEW N b CC Link master module setting Set the CC Link master modules as follows 1 When mounting to the main base unit z O T 5 o Le Z Q SYSTEM e System A master station e System B standby master station If A system is standby master station and B system is master station data link cannot be made Also start the system so that A system can be the control system C gt Section 5 1 2 If B system starts as the control system CC Link communication cannot be
392. monitor status control system standby system and System A System B Contd system SystemA 11 0010ns Pon _a refs el ame afsl l zmo Hel e HEE m ial Bee eke en a a eal f 1 eu 4 a Sg man Project B re Host stat Display information for the system specified in connection settings control system standby system and System A System B Diagram 6 2 GX Developer Ladder Monitor Screen 6 1 Communication with GX Developer and PX Developer 6 1 2 Confirming the Connection Target on GX Developer 6 REDUNDANT SYSTEM NETWORKS M als 26 fel ceries 6 1 3 Cautions on Access from GX Developer and PX Developer This section describes cautions on access from GX Developer and PX Developer ai x u 1 Cautions when the System Connected to GX Developer PX Developer and the Specified System are Different a Communicating with a CPU Module via a Tracking Cable S When the system for the CPU module to which GX Developer PX Developer is r connected is different from the specified system communication is done with the 3 CPU module of the other system specified system via the tracking cable 2 nO C gt Table6 1 E o n SEE a JS 5 g a _ 4 3
393. n No of systems A and B to monitor when system switching occurs For details refer to the following manual L gt GOT A900 Series User s Manual GT Works2 Version2 GT Designer2 Version2 compatible Connection System Manual 6 49 6 3 Communication between the Both Systems CPU Module and GOTs 6 3 3 Communication when the GOT is Connected to CC Link IE Controller Network MELSECNET H or 6 REDUNDANT SYSTEM NETWORKS MELSEC TE eries 6 3 4 When Connecting GOTs to a Ethernet The GOT is connected to Ethernet module mounted on the main base unit or Ethernet ai module mounted on the extension base unit i 6 1 GOT Connection Methods Connect GOTs to a Ethernet via Ethernet connection 6 GOT1000 series E GOT A900 series Ethernet connection fa o nZ Ethernet aS System A Station System B Station Control system No 1 Standby system No 2 i i Lu a lt oO o Z w Diagram 6 38 GOT Connection Type when Mounting to Main Base Unit z System A Control system System B Standby system re al ros e Dog a DES 8 om ZEA anr Lu D gt N S zn 66 Ethernet 55 az W D ew GOT1000 series Ethernet connection ez Diagram 6 39 G
394. n in progress XnE XnF ERR occurrence ON Error occurring X n 1 E Q series C24 ready ON Accessible ON Module error occurred Watchdog timer error X n 1 F OFF Module being normally WDT error operated Yn0O Yn7 Transmission request ON Requesting transmission 3 Buffer memory Table App 35 List of Buffer Memory Buffer memory address Hexadecimal decimal Stored value CH1 side CH2 side 0 0 1401 Communication error clear 0 OFF No initialization request 5 i request and to turn LED off 1 OFF Initialization requested 0 Word units 96 150 136 310 Word byte units designation a 1 Byte units 4004 to 1AFF AOp 160 140p 320 Buffer memory head H H address for on demand 2600 to 3FFFy A14 161 14114 321 On demand data length 00004 to 34004 201 4 513 LED ON status and 0 Turned off OFF no error communication error status 1 Turned on ON error 0 Completed normall 2561 598 266 4 614 On demand execution result z 1 or later Error code C00 to 1AFFy User free area 3072 to 6911 Appendix 6 6 ONDEMAND Instruction APPENDICES MELSEC Asri The program example of sending data by the on demand function is shown in Diagram App 31 For the I O signal is X Y80 to X Y9F X9E X9F reesen cee ee nnn ence een eee ee eee een e mens o
395. n 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 2 Ifno 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 module both system CPU modules judge it as the failure of the online program change for redundancy In this case both system CPU modules re k resume the consistency check between system A amp B suspended during the Waiting time for online program SD1710 online program change Also the control system CPU module is set to accept a change standby system new request of online program change for redundancy 3 When both systems are powered on 90 seconds are set to SD1710 as the default value 4 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 5 The waiting time for a start of online program change to the standby system CPU module is checked with the SD1710 setting during redundant tracking of multiple block online program change or online file writing REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS
396. n 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 2 E zZ control system CPU module when the control system CPU module is in the 2 STOP status and the standby system CPU module is in the RUN status 5 To disable system switching at the time of remote reset change the operation gt statuses of the control system and standby system CPU modules to the STOP ae status and then perform remote reset Control STOP Reset Standby RUN m Remote operation a Connection target information system system amp Connection interface COMI lt gt PLC module a B al E E B al Ta 2 Target PLC Station no Host PLC type Q25PRH B 5 5 PLC status STOP E Jel E B el Fo 5 systemyee Eome o Operetonmede Backup mode a Gl gi CH 3 z Operation Specify execution destination z pic Reset Currently specified station Tracking cable 2 All stations Extract memory card ese c a gt N 255 System switching aes GX Developer ORS C Eeue 2 9 an Control RESPE STOE Standby system E f Hl fac Is A al BIE 5a i x z fe 2 j O pa i Ze F JE D r L ag Sy BE 3 rare Tracking cable W D gt N Fay GX Developer lt fe Diagram 5 104 Remote Reset Operation When Control System CPU Module Is in STOP Status and Standby System CPU Module Is 5 in
397. nd a system 49H sD1601 Ki6 SD1602 K2 JH 8E M100 switch has occurred sets the control program execution flag to ON M101 X41 SM1515 SM1516 SB47B 56 RK S a A SP CONTSW K2 M202 Switches the system when System B has started first SET M102 Set System B first startup system change flag to ON 70 FEND End main routine program 141 M102 1 SET SB40C Set CC Link forced master switching flag to ON 74 IRET End interrupt program Diagram App 11 A sample program of CHANGE Appendix 4 Sample Programs when Using CC Link App 24 Appendix 4 5 Sample Program APPENDICES MELSEC LAY eries 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 18 END Diagram App 12 Sample program overview flow 2 Sample program S402 0 HR gt pT M100 X40 X4F X41 SB47B M100 j _ A aSs 0105 31 P1 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 ae a ea cee E E EE ee ee ee P1 END Diagram App 13 A sample program of MAIN App 25 Appendix 4 Sample Programs when Using CC Link Appendix 4 5 Sample Program APPENDICES Appendix 5 Method for Starting up the Previous Control System MELSEC TE cries When both systems are simultaneously powered on o
398. nd remote I O station oH When an error fuse blown or module verify error occurs in a Redundant CPU remote master station and a remote I O station the data link and output of the z remote I O station is determined by the combination of the error time operation mode E Pa settings of the Redundant CPU remote master station and remote I O station 2 Z 2 The following describes the data link and output status of the remote I O station 6 determined by the combination of the parameter settings AZ ew a Operation when error occurs in Redundant CPU remote master station 6 Table6 3 Operation When Error Occurs in Redundant CPU Remote Master Station z Settings of operation mode for gt Data link operation of i error occurrence Redundant CPU Output operation from remote z9 MELSECNETIH remote I O i efa Redundant Remote I O control status I O station 53 i network oF CPU station XZ Stop Depends on the output mode Stops control p Stop All stations stop data link hold clear settings for error Continue Stop error 3 occurrence o Stop Continues control P Z Continue All station continue data link All stations output normally Ea Continue Continue error ss ao 2 Refer to the following manual for details of the PLC RAS setting QCPU User s Manual Function Explanation Program Fundamentals 3 Set the output mode for error occurrence in the I O assign
399. ndant system without making any modifications fi N Some models are irrelevant Section 2 3 7 Therefore equipments within factories can be utilized maintenance costs can be Z O reduced and the system can be expanded 55 rad o o 56 oo ao o z o O 35 if a O ao 1 2 Features 1 13 1 OVERVIEW MELSEC TE cries 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 lt Section 2 4 6 The module can be replaced without stopping the system when it fails Note that a module mounted to the main base unit cannot be replaced online when the extension base unit is connected Control system Standby system 2 in im c o o 3 B El 8 5 5 El EB a El P S 4 z e lel E lel la i i O e a m a B 8 p g eH Failed i module Tracking cable MELSECNET H Remote I O network _ Remote I O station Remote I O station 2 Online module change hot swapping Eo
400. ndby system CPU module from the main base unit Mount an alternative CPU module 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 Connecting the Tracking Cable Connect the tracking cable connector to the standby system CPU module Refer to Section 3 3 for connecting the tracking cable Power ON the Standby System 1 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 t Confirming the POWER LED of the Power Supply Module Confirm that the POWER LED of the power supply module is ON lit green and the module is being properly powered 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 Resetting the Standby System CPU Module l 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 sa
401. nding 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 MELSEC Q L Serial Communication Module User s Manual Application This manual contains information on how to perform data communication with external devices using the module 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 programmable controller CPU status monitoring function the communication function via MELSECNET H MELSECNET 10 as well as the communication function using data link instructions and how to use file transfer FTP server etc Sold separately MELSEC Q L MELSEC Communication Protocol Reference Manual This manual explains the communication methods and control procedures through the MC protocol
402. ng cable i e connectors 1 Determination of System A System B The system that includes the CPU module connected with the tracking cable system A connector will be System A and the other one with the system B connector will be System B 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 System A System B Deol 16st Tracking cable System A connecter System B connecter i Im A B 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 System B System A Fao ea 15 GAINA Ja aAa Ji i S e E 7 Tracking cable
403. ng cable Connector Z 5 BS m m uw d Tighten the connector fixing screws and fix the connector to the CPU module W D Connector screws A E Flathead screwdriver 2 g Q ZO Be W Ww ez S Diagram 3 4 Fixing the Tracking cable Connector 32 a z3 ao zZ fe E N 5 a 5 ao 3 3 Connecting and Disconnecting a Tracking Cable 3 3 TRACKING CABLE MELSEC TA eries 3 Disconnecting a Tracking Cable a Loosen the connector fixing screws 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 sT Redundant CPU gi TRACKING connector Z Connector X Tracking cable Diagram 3 6 Disconnecting the Tracking Cable 3 3 Connecting and Disconnecting a Tracking Cable 4 PROCEDURE FOR STARTING UP A REDUNDANT Se M IES 26 FY aries CHAPTER4 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM S 1 Procedure for starting up in backup mode The standard procedure for starting up system A as the control system and system B as the standby system of a redundant system in the backup mode is shown below Explanation of program and parameter creation is not provided here chs Section 4 1 Mount the power supply module CPU module network module and I O module to the main base ih l Refer to S Section 4 2 E Connect the power cable to the power supply mod
404. ng can damage the screw and or module resulting in drop short circuit or malfunction When using an extension cable connect it to the extension cable connector of the base unit securely Check the connection for looseness Poor contact may cause incorrect input or output When using a memory card fully insert it into the memory card slot Check that it is inserted completely Poor contact may cause malfunction Shut off the external power supply for the system in all phases before mounting or removing the module Failure to do so may result in damage to the product A module can be replaced online while power is on on any MELSECNET H remote I O station or in the system where Redundant CPUs are used Note that there are restrictions on the modules that can be replaced online and each module has its predetermined replacement procedure For details refer to Section 2 4 Do not directly touch any conductive part of the module Doing so can cause malfunction or failure of the module When using a Motion CPU module and modules designed for motion control check that the combinations of these modules are correct before applying power The modules may be damaged if the combination is incorrect For details refer to the user s manual for the Motion CPU module A 3 Wiring Precautions WARNING Shut off the external power supply for the system in all phases before wiring Failure to do so may result in electric shock
405. ng 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 used will be tracked e Divide the tracking data range into multiple blocks and change the tracking timing for each block To add file register or Set the file register or annunciator to tracking blocks annunciator No 1 to 64 e Change the settings so that the tracking trigger of tracking block No 1 will be turned on and off manually e Divide the tracking data range into into multiple blocks and turn the tracking trigger of each block on and off in the program To shorten tracking time Program tracking timing to any time b Signal Flow Memory Signal flow memory records the operation execution result of each sequence program step i e whether each sequence program step was executed or not 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 When signal flow memory has not been tracked the rise fall and SCJ instructions may not function normally in the new control system after system switching In order to ensure these instructions function even if system switching occurs change the settings so that signal flow memor
406. nnected to the CC Link IE Controller Network or MELSECNET H PLC to PLC network After starting up system A and system B the control system and standby system are determined and then the data link is continued 6 2 Redundant System Network Overview 6 2 1 CC Link IE Controller Network or MELSECNET H PLC to PLC network 6 REDUNDANT SYSTEM NETWORKS MELSEC TE eries 7 Precautions for Using Redundant System in CC Link IE Controller Network or MELSECNETI H PLC to PLC Network a Programming of CC Link IE Controller Network or MELSECNET H CC Link IE Controller Network or MELSECNET H network detects a temporary communication error depending on conditions such as power supply ON OFF or cable and noise Create the program using CC Link IE Controller Network or 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 CC Link IE Controller Network interface board or MELSECNET H board is mounted CC Link IE Controller Network module or MELSECNET H module of the control system may issue a system switching request detecting a temporary communication error When the above mentioned system switching request is issued before the standby system is started up a
407. not request system switching even if the module detects a module fault or communication failure with DP Slaves When receiving the system switching request from the network module the control system CPU module will perform a system switching at END processing CONFIGURATION SYSTEM Diagram 5 24 shows the processes that take place when the system switching request is received from the network module TRACKING CABLE Ethernet Communication error or System A disconnection System B Control System Standby System E 5 LIL g System switching request HTE O g A is al J Ei System A System B z 7 a oo0000 nooo mg REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ieoTsNe oTsts coag oong RUN Control Execute program system Standby Tracking cable system N Normal Standby i RUN ee System switching Stop program System switching requested by the i SZ Ethernet interface Y module END System Ethernet a m switching 2 nication Control start System B i Standby System Normal Standby PRH Control System RUN Stop i Jen ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O
408. ns ON the read request signal Reads result of read if read completion signal is turned ON Turns OFF the read request signal Reads the number of user registration frames Converts the number of bytes into the number of words Add 1 to the number of read ll words for the odd data Reads the user registration frame Resets the read flag Appendix 6 Precautions for Using Serial Communication Module App 46 APPENDICES MELSEC KE eries 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 PROCESSING TIME FOR REDUNDANT SYSTEMS 1 Device of programmable controller CPU Table App 33 Device Used in the Program Device No Application Remarks X50 Transmission command ON Transmission completion it X60 Error reset command ON Error reset 9 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 demand data set 2 W O signal Table App 34 List of I O Signal INDEX V O signal 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 Transmissio
409. ns at System Switching Occurrence PROGRAMMING CAUTIONS MELSEC TE eries 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 Pe O E Response input X10 X g l 2 OZ O LJ pl nO Output Y10 Program example g 9 zZ Before measures 5 Mo x0 Y10 i yF Ff SET Y10 M10 X10 yY10 i z RST Y10 pe i L oe woe ags WEZ Or After measures TED an M1 i i SET Y10 i meet r Delays SET Y10 by one E PLS M1 H g H scan from PLS M1 a 5a M11 z RST Y10 SE 50 az W D S ied es r q Delays RST Y10 by one m KS KS PLS M11 H m scan from PLS M11 W G Diagram 7 17 Program Example when there is Response Input to Output E Zn gi ZO ae Lu Lu ez bas z o a g OF o3 E ao TROUBLESHOOTING 7 4 Precautions at System Switching Occurrence T 19 PROGRAMMING CAUTIONS MELSEC Aeres b Output is returned corresponding to external input Response input X10 X i o Output Y10 Program exam
410. nsion base unit refer to Ew Section 2 4 4 Be W Ww rz 9 zZ 22 6 z2 ao 9 zZ fe E N W l a 5 1 2 Features 1 7 1 OVERVIEW MELSEC Aries 3 Network Configuration Including Redundant System a CC Link IE Controller Network MELSECNET H PLC to PLC Network and Ethernet In the case of CC Link IE Controller Network 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 OPS Normal station Control station Normal station ia CC Link IE Controller Network interface board CC Link IE Controller Network Control system Standby system Normal station Normal station Ae ale Le g A o kd e 2 GE E g e H a Tracking cable Control station Normal station o OPS Normal station CC Link IE Controller Network interface board 1
411. nted on a main base unit COCCOO OOOO OO OOO OOOOH OOOO OOO OOOOH OOOO OOO OOOO OOOO OOOOOOOOOS 2 1 9 Number of slots occupied by a Redundant CPU SOHOHSOHOH SH SSH SH SHHSHHHHOHHHOHHOHOSOHSHOHSSHSHOSOHSHOOHOOOOS 2 21 Restrictions on online module change Hot SWAPPING soeeeeeeccccccccccscccscccsccscccsccccocscocs 2 22 Restrictions on use of extension base units 2 19 System A system B configuration sessesessesseese 2 21 System fault information eeccccccccccccccccccccccccceee 555 System switch FESUItS ccccccccccccccccccccccccccccccccce 5 55 System switching by the system switching instruction SOOHOHOSHSOHSOHSHSSHSSHSH HSH OHH OH OHOHHOHHOHOHHSOHSSOHSOHSHHOHOOOEE 5 39 System switching condition eececcccccccccccccccccccece 5 54 System switching dedicated command parameter SOOHOHHSHSOHSOSSHSOSHSSHSH SSH OH HSOSHHHOHHHHOHOHHOHOSOHSOHSHOOSOOEOS 5 55 System switching disenabling Conditionsssssssss999 5 54 System switching during online program change SOOHOHOSSOSOSH SHS HHS SHSHHSH HHH OHSHOHHOHOHOHHOHOSOHSOHOHOOOOOS 5 105 System switching execution possibility s s 5 44 5 49 System switching execution timingesessssseseeseesee 5 43 System switching function ceccccccccccccccccccscvcscce 5 33 System switching MethOd ecececccccccccccccccccccccese 5 33 System switching precautions rerseesesceseeseeseeses 5 56 System switching PIiOrity sercccecccecccccccccccccccccce 5 41 System switching requested by the network module SOOHOHOSSOSSS SH SOS SHSHHSH HHH OH
412. ntelligent function module that supports online module change lt 3 Section 2 4 6 PROGRAMMING CAUTIONS TROUBLESHOOTING 5 2 FUNCTION LIST 5 32 D REDUNDANT SYSTEM FUNCTIONS MELSEC TA eries 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 Operation Modes e System switching when a fault occurs in the control system Automatic system ADAR ee itchi e System switching by the system switching request issued from Backup Mode switchin e the network module Manual System Switching e System switching using GX Developer Backup Mode e System switching by system switching instruction Separate Mode 1 System switching can be done from the OPS
413. ntrol system 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 12 Online module change oN e 5 53 5 3 The System Switching Function 5 3 5 Special Relays Registers For System Switching OSet Not set D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries Table5 39 Special Registers For System Switching Continued Setting at Time of System Switching Device No Description 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 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 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 success
414. o 3 Station No 4 6 Fa 2S nO CC Link IE Controller Network Communication Q error Control station Normal station amp Control system St Standby system _ L Station No 2 g i System switching request Q a fl f a O Toli g Tracking cable a x Operation when a communication error occurs ire eS a lt l e in the MELSECNET H PLC to PLC network voz Normal station mae Station No 3 ome o S X EU g ane US A g 5 A AE Lu D N 1L CC Link IE Controller Network gt 2 ZF Normal station Normal station Station No 2 a z n Station No 1 Sub control station rn Standby system Control system 6 f J A z Al fe The new control system s peerd z a normal station becomes the P E pa 5 sub control station and a E maintains the data link SI g Tracking cable J Lu wn gt no j A Ed a Zz fa W a n X x e z E W zZ Diagram 6 9 Continuation of Data Link via System Switching PROGRAMMING CAUTIONS TROUBLESHOOTING 6 2 Redundant System Network Overview 6 12 6 2 1 CC Link IE Controller Network or MELSECNET H PLC to PLC network 6 REDUNDANT SYSTEM NETWORKS M ELSEG Q series b Operation of New Standby System Network Module The new standby system network module that has developed a communication error is cu
415. o Z O O Z Le The following stop error will occur only in the standby system CPU module only FILE DIFF error code 6000 2 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 REDUNDANT SYSTEM NETWORKS 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 PROGRAMMING CAUTIONS 2 Ifa stop error occurs in the standby CPU module the STANDBY SYS DOWN error code 6300 continuation error will occur in the control system CPU module TROUBLESHOOTING 5 1 Basic Concept of Redundant System 5 18 5 1 4 System Consistency Check D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries 2 Operating Status Consistency Check a Check points The operating status consistency check means checking the CPU module operating status RUN STOP PAUSE Control system Standby system Control System fa o a System switching z g activated Refer Section 5 3 for a system switching f Sl as causes 5 ooo000 ooo000 nooo
416. o i DUTY K1 K3 SM420 instruction during SE SM1518 shutdown ex Diagram 7 7 Program That Executes Fixed scan Clock SM420 after System Switching 4 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 and Fixed Scan Execution Type Programs T 9 PROGRAMMING CAUTIONS T 10 MELSEC TE eries 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 when q a Control system R New standby system System switching activated fixed cycle execution type Control system Program z z Scan execution type y i y y Program New standby system a a Standby system Begin system switching as System Switching complete fixed cycle execution type x sg Program Se bio t New control system Sean execution type EET so Program Extension of fixed cycle interval Standby system New con
417. ocessed Not processed Access Request from Intelligent Function Module 5 51 Ignores the access request Not processed 1 The redundant CPU cannot execute the low speed execution type programs 5 3 The System Switching Function 5 3 4 Both Systems Operations After System Switching D REDUNDANT SYSTEM FUNCTIONS 2 Network Module Operations MELSEC KE eries Table5 37 Control System and Standby System Network Operations After System Switching Item CC Link IE Controller Network New Control System Network Module Starts cyclic transmission New Standby System Network Module Continues cyclic transmission However does not perform output MELSECNET H PLC to PLC network Starts cyclic transmission Continues cyclic transmission However does not perform output MELSECNET H Remote I O network Starts cyclic transmission Operates as master station Continues cyclic transmission as sub master station However does not perform output Communicates with the control system when it is specified by external device Communicates with the standby system when it is specified by external device Ethernet m 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 PROFIBUS DP Continues PROFIBUS DP communications Stands by and prepares for system switching R
418. odule as a standby system REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS o e o zZ O O ol w l D 2 O hA 8 1 Troubleshooting Flow 8 20 8 1 8 When CONTROL SYS DOWN error code 6310 to 6312 Occurred at Redundant System Startup 8 TROUBLESHOOTING MELSEC Kel ries 8 1 9 When ETX CABLE ERR Occurs The following shows the flowchart for when EXT CABLE ERR occurs during operation of the redundant system Error message EXT CABLE ERR was detected Are main base unit of control system and Q65WRB connected by extension cable Turn OFF power supply of control system Connect OUT connector of main base unit of control system and IN1 IN2 connector by extension cable Are main base unit of standby system and Q65WRB connected by extension cable Turn OFF power supply of standby system Connect OUT connector of main base unit of control system and IN2 IN1 connector of Q65WRB by extension cable Turn ON power supply of standby system Turn ON power supplies of control system and standby system again Does EXT CABLE ERR occur again Hardware failure of the following modules is suspected CPU module Main base unit or extension base unit Extension cable Consult your local Mitsubishi service representative explaining a detailed description of the problem D
419. ommunication 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 2 When Control System 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 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 M IES 26 fel ceries
420. on 1 When CC Link IE Controller Network modules are mounted do not connect the CC Link IE Controller Network module on both systems to the network at the same time In the debug mode the system B CPU module uses the same parameters for the system A CPU module for operation Therefore control station overlap and station number overlap occur when connecting to the network at the same time 5 13 5 1 Basic Concept of Redundant System 5 1 3 Operation Mode D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries 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 S x 1 Write the redundant parameter in which Start with Debug mode is set into the 3 CPU module and power on the system again or set the RESET L CLR switch of the CPU module to reset switch neutral position Then the system will start up in the debug mode ra System A e Control 3 Reset the CPU module Z System 4 Debugging standalone system z D 5 2 nO 2 Write parameters to the j 1 Debug Mode Setting Lu Select Start with Debug a i Mode o o zZ x O GX Developer es p s fu x Sag a eee 55 Diagram 5 9 Setting of Debug Mode on Redundant Parameter Screen E a anr 2 Write the red
421. on Diagram 2 7 Connection of Redundant System to CC Link 2 10 2 1 System Configuration 2 SYSTEM CONFIGURATION M IES 26 Kel ceries 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 OVERVIEW N 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 T 5 o Le Z Q SYSTEM manual W C gt PROFIBUS DP Master Module User s Manual a S o Control Master Standby Master Z 6 System A Control System System B Standby System E 5 Z gt S J z gt 5 c 5 3 5 J amp E uls 8 5 J lE a s8 E x h x x A 2 gt a N a gt ing N _ 7 W a a 2Dlo OGInr rom A RDlo lOGInr x D 2 e e a S ie gt Omi 3 G fe fej FI E G CG TI W 5 H 5 5 E z z nzo 5 0 Deg a a 3 amp 2 X EU z an Tracking cable W D PROFIBUS DP o OU E 6 ZE DO A A EE DP Slave DP Slave DP Slave DP Slave ai Diagram 2 8 Connection of Redundant System to PROFIBUS DP wn Zv ou zo ae W Ww ez o zZ o 56 ra ao zZ fe E N
422. on Stores system switching condition in SD1601 on both systems at system switching e Initializes at 0 at power OFF ON reset reset clear The values stored in this register are as follows 0 Initial value system switching has never occurred O O 1 System Switching SD1601 Results 1 Power OFF reset hardware failure or watchdog timer error 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 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 parameter SD1601 SD1602 only changes during execution of system switching due to a control system switching instruction 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 SD1610 Diagnostic Error OSet Not set 1 Does not store 1 in new standby system SD1601 when switching due to control system power OFF or reset 5 55 5 3 The System Switching Function 5 3 5 Special Relays Registers For System Switching D REDUNDANT SYSTEM FUNCTIONS MELSEC TE
423. on 1 00A or later is applicable Instruction restriction Instructions listed in Table App 7 are inapplicable Program App 11 Low speed Execution Type Program N A Appendix 3 Comparison of QNPHCPU and QnPRHCPU Applicable APPENDICES MELSEC TE eries Table App 7 Instructions Inapplicable for QNPRHCPU 2 lt x Instruction i Instruction g 2 z Instruction Name Instruction Name eae Symbol Symbol uw Fa E PLOADP Program Load from Memory Card PLSY Pulse Output g 5 A 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 D P SFCF Request of Motion SFC Program Startup KEY Numerical Key Input D P SVST Request of Servo Program Startup 2 Axis Speed Change during Positioning and JOG 2 UDCNT1 1 phase Input Up Down Counter D P CHGV j Z operation w Q Torque Control Value Change during Operation and lt UDCNT2 2 phase Input Up Down Counter D P CHGT A Suspension in Real Mode Current value Change of Halted Axis Synchronized TTMR Teaching Timer D P CHGA Encoder Cam axis f Write Host CPU Device Data into Other CPU STMR Special Timer D P DDWR devices ROTC Rotary Table Near Path Rotation Control D P DDRD Read Other CPU Device Data into Host CPU x lu RAMP Ramp Signal 2 D P GINT Request of Other CPU Interrupt Program
424. on 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 13 Delay Information Setting Use the link scan interval as O Default 14 Station Information Setting Set the station information to Station Information Settings as shown in Diagram App 5 CC Link station information Module 1 Station No Station type cyclic setting count points station select Automatic 121 Remote 1 0 station single Exclusive station 1 v 32 points No setting v Remote 0 station Exclusive station 1 v 32 points v Nosetting v z at Remote device station sinde Exclusive station 2 64 points v No setting e e Intelligent device station singe Exclusive station 32 points v No setting X Default Diagram App 5 CC Link Station Information Setting App 19 Appendix 4 Sample Programs when Using CC Link Appendix 4 4 Parameter Settings APPENDICES MELSEC TE eries Appendix 4 5 Sample Program 1 When the QJ61BT11N s serial No first 5 digits is 07112 or later PROCESSING TIME FOR REDUNDANT SYSTEMS a Sample Program Name CHANGE 1 Sample program overview flow
425. on of the CPU module can be confirmed on the rated plate OVERVIEW N MELSEC Q MITSUBISHI MODEL Serial No first 5 digits function version z O T 5 o Le Z Q SYSTEM SERIAL 0000000000 D Relevant regulation standards we MITSUBISHI ELECTRIC MADE IN JAPAN N Diagram 2 10 Rated plate a S 0 z 5 b Checking on the front of the module The serial number written on the rating plate is displayed on the front at the bottom of the module X y Oa gt A a lt Q25PRHCPU woe 204 MODE BACKUP a 9 RUN coRo om ERR sista I Qe USER SYSTEMB C ange BAT BOOT Lu TRACKING E N Zn 56 Ze DOG az Zr pe a ee a BN E Ba W _ D vy N zg j aa Z O L d 2E W Ww ez Diagram 2 11 CPU module front display o z CD ooo ooo coer o 26 The serial number is displayed on the front of the module from March 2008 95 production nied Products manufactured during switching period may not have the serial number on the front of the module o eeeeeeeoeceoeseeoeeeeeaeeeoeeeeoeeoeeeaseseeeeeeeeeoeeae eee eeeeee ee 2 if a O ao 2 3 Applicable Devices and Software 2 15 2 SYSTEM CONFIGURATION 2 16 MELSEC TE cries c
426. onitor MELSOFT series GX Developer x MELSOFT series GX Developer X i The module start address is incorrect i The device No is outside the range Enter the correct module start address Check using the parameter device 5 Input X from the input module on the extension base unit will be an undefined value 5 11 Access to Module Mounted on Extension Base Unit 5 140 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING 6 REDUNDANT SYSTEM NETWORKS Ml ELSEG Q series CHAPTER6 REDUNDANT SYSTEM NETWORKS This chapter explains the redundant system networks on the assumption that the operation mode has been set to backup mode 6 1 Communication with GX Developer and PX Developer 6 1 1 Communication Methods with GX Developer The communication between GX Developer and redundant CPU module can be made through the following three paths e CPU module direct connection e Routing a network module e Routing an intelligent function module In the case of GX Developer select Online Specify Connection from the menu bar and specify the connection path on the displayed dialog box And specify the communication target system from the following Not specified default Control system Stan
427. oooooocoooooooooooo000000000000000000000000000000000000000000000000000 D 1 5 1 1 Determination of System A System B seeseeesesesesececececcececococososcsssesesesesesesesececeoeosesoee5 3 5 1 2 Determination of Control System and Standby System eeseeeeeseeseeseeccesceccecoecoeccescesceesee 5 5 5 1 3 Operation Mode sseeseeesesssseeecesssesceccocssssosccesocososccesoossoscsocossssoscecesssssccccoessssssseees 5 _ 9 5 1 4 System Consistency Check eeseseseseseseseseseseseseceococococoeososososssesssesesesesecececeosesesese 5 16 5 1 5 Self Diagnostics Function seesesesesesesesesesesesecececeocecocososoocsoscocsseseseseceseseceoeceesesesose 5 26 5 1 6 Start Mode COC COOO OOO OO OOO OOOOH OOOO OO OOO OOOO OOO OOO OOOOH OOOO OOO OOOOH OOOO OOO OOOO OOO OOOO OOOOH OOOO OOO OOOO OOOOSOOCE 5 29 5 2 FUNCTION LIST COCOOOOOO OOOO OOOO OO OOO OOO OOOO OOOOH OOOO HOO OOO OOOO OOO OOOO OOO OOOOH OOOO OOO OOO OOOO OOOO OOOO OOOO OOOES 5 32 5 3 The System Switching Functione eseeeeeeeeesesssessseseseseecececececececececoococosceossossesosesssesesesesee 5 33 5 3 1 System Switching Method eeeesesesesesesesesesesececececoococososooososcossesecesesesececececsesesossse 5 33 5 3 2 System Switching Execution TimMinge eeeeseseseseseeeceseeseessoeossooscsseoeseseseseseceoeosesesosose 5 43 5 3 3 System Switching Execution Possibility seeeseseseseeeseesesesseccoscosscseseseseseseceoeceesesosose 5 44 5 3 4 Both Systems Operations After Syst
428. op circuit protection circuit and protective interlock circuit for forward reverse operation or upper lower limit positioning 2 The programmable controller stops its operation upon detection of the following status and the output status of the system will be as shown below Overcurrent or overvoltage protection of the power supply module All outputs are turned off is activated The CPU module detects an error such as a watchdog timer error All outputs are held or turned off according to by the self diagnostic function the parameter setting All outputs may turn on when an error occurs in the part such as I O control part where the CPU module cannot detect any error To ensure safety operation in such a case provide a safety mechanism or a fail safe circuit external to the programmable controller For a fail safe circuit example refer to Chapter 10 LOADING AND INSTALLATION in the QCPU User s Manual Hardware Design Maintenance and Inspection 3 Outputs may remain on or off due to a failure of an output module relay or transistor Configure an external circuit for monitoring output signals that could cause a serious accident A 1 Design Precautions WARNING In an output module when a load current exceeding the rated current or an overcurrent caused by a load short circuit flows for a long time it may cause smoke and fire To prevent this configure an external safety circuit such as a fuse Configure a ci
429. 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 gt Annunciator detection to The annunciator No turned on is stored 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 Control system System B Standby system LED status a LED status USER m A B USER E Program l a z a Program MO a B MO oser F10 H Tracking ca
430. or damage to the product After wiring attach the included terminal cover to the module before turning it on for operation Failure to do so may result in electric shock CAUTION Ground the FG and LG terminals to the protective ground conductor dedicated to the programmable controller Failure to do so may result in electric shock or malfunction Use applicable solderless terminals and tighten them within the specified torque range If any spade solderless terminal is used it may be disconnected when the terminal screw comes loose resulting in failure Check the rated voltage and terminal layout before wiring to the module and connect the cables correctly Connecting a power supply with a different voltage rating or incorrect wiring may cause a fire or failure Connectors for external connection must be crimped or pressed with the tool specified by the manufacturer or must be correctly soldered Incomplete connections could result in short circuit fire or malfunction Tighten the terminal screw within the specified torque range Undertightening can cause short circuit fire or malfunction Overtightening can damage the screw and or module resulting in drop short circuit or malfunction Prevent foreign matter such as dust or wire chips from entering the module Such foreign matter can cause a fire failure or malfunction Wiring Precautions WARNING A protective film is attached to the top of
431. or later 2 4 Ver 6 20W or later Product Name SW8D5C GPPW E SW1D5C FBDQ E SW6D5C LLT E GX Developer PX Developer GX Simulator z O lt 5 o Le Z Q SYSTEM 1 Use version 8 45X or later when using extension base unit 2 Use version 1 14Q or later when using extension base unit 3 Use version 8 68W or later when using CC Link IE Controller Network module i 4 Use version 1 18U or later when using CC Link IE Controller Network module a S b Available GX Configurator versions 2 EA Table2 3 shows GX Configurator versions supporting redundant system Table2 3 Available GX Configurator versions Product Name Model Version GX Configurator CC D5C J61P E Ver 1 10L or later 5g GX Configurator AD D5C QADU E Ver 1 15R or later g z z Q Q GX Configurator DA D5C QDAU E Ver 1 15R or later 3 Z lt GX Configurator SC D5C QSCU E Ver 1 14Q or later aoa GX Configurator CT D5C QCTU E Ver 1 16S or later GX Configurator TC D5C QTCU E Ver 1 14Q or later s Lu GX Configurator T D5C QTIU E Ver 1 14Q or later N GX Configurator FL D5C QFLU E Ver 1 14Q or later z 2 O GX Configurator PT D5C QPTU E Ver 1 14Q or later z 5 az GX Configurator AS D5C QASU E Ver 1 16S or later ZR GX Configurator QP D5C QD75P E Ver 2 14Q or later GX Configurator MB D5C QMBU Ver 1 00A or later
432. or the Operation Specify execution destination CPU module of the pic stop gt C Cumently specified station system specified in E C Al statons Connection Setup C Specific group 7 bees Select when performing remote operation for the control system and standby system CPU modules Diagram 5 98 Remote Operation Screen 5 10 Redundant CPU Functions Restricted in Redundant System 5 10 2 Remote Operation for Redundant System D REDUNDANT SYSTEM FUNCTIONS M als 26 Le ceries 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 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 OVERVIEW CONFIGURATION SYSTEM Control system oll l6olz
433. orm PLC write to control CPU module GX Developer Program memory Program memory Perform PLC write 7 for program B Before writing After writing Before writing After writing Program A Program A Program A Program A Program B Program B Diagram 5 59 Procedure for Writing to the Control System and Standby System When CPU Module Writes Program during STOP 5 6 Online Program Change for Redundancy 5 96 5 6 1 Writing to the CPU Module in STOP Status OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu wn gt wn Zz a a rs 2D fa Lu a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series 3 Precautions a If programs cannot be written to the standby system CPU module In the following cases the data will be written into only the CPU module to which GX Developer is connected Either or both powers on control system standby system are OFF e Either or both CPU modules on control system standby system are in RESET Either or both systems have a hardware failure Either or both CPU modules on control system standby system have Watchdog timer error error code 5000 or 5001 e Tracking cable disconnection or malfunct
434. ot executed write 1 to the following address Table App 20 List of Buffer Memory Buffer memory address Hexadecimal decimal CH1 side CH2 side A84 168 148 328 Receive data clear request Buffer memory name Ee 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 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 36 Appendix 6 1 CSET Instruction APPENDICES MELSEC LAY eries The program example of clearing receive data is shown in Diagram App 26 For the I O signal is X Y80 to X Y9F X23 0 PLS M15 Accepts the receive M15 data clear request 3 SET M16 M16 M11 M12 M17 M18 1X83 X84 R iih y jy i r q Requests the receive 5 HH AA HFT H8 HOA8 K1 K1 T data clear mee J 4 E A SET M17 Turns ON the receive data clear completion flag M17 A Reads the receive 18 FROM 8 HOAB BO Ki data clear status DO KO RST M16 Resets the receive data clear flag RST M17 SET M18 J4 MS H E a kes the 100ms dat Makes the ms data i 30 T100 1 communication to be A disabled aft
435. ote Remote device Intelligent device D base unit 2 I O station station station Bm 6 ZE Personal AnACPU AnUCPU AnNCPU az computer Normal station Normal station Normal station wi lt CMELSECNET H MELSECNET 10 Mode PLC to PLC network communication with other stations gt fi 3 5a QCPU QnACPU Q4ARCPU ax MELSECNET H Remote I O network Normal station Normal station Normal station E I O control communication with external systems Control station re Remote Remote Remote I O station I O station I O station o Diagram 2 1 Example of Redundant System Configuration Z 2 OF z2 1 In a coaxial bus system use double shielded coaxial cables ZC Refer to the following manual for the double shielded coaxial cables L7 Q Corresponding MELSECNET H Network System Reference Manual Remote I O Network S 2 For the extension base units and network modules compatible with the redundant system refer to S Section 2 3 and Section 2 4 F 5 ao 2 1 System Configuration 2 1 2 SYSTEM CONFIGURATION MELSEC TE cries 1 Redundant System a J POINT 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 system
436. oup Settings 5 126 D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q 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 Enforced ON OFF of external I O e Remote operation Refer to the following manual for details of each function lt gt QCPU User s Manual Function Explanation Program Fundamentals 5 10 1 Enforced ON OFF of external I O 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 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 standby system CPU the error dialog box in Diagram 5 96 will appear on GX Developer In this case change the connection target of GX Developer to the control system Ml MELSOFT application E MELSOFT application i This Function cannot execute with control system of transfer setting or standby system of transfer setting A Please change transfer setting and execute it again i L The executed function is not supported in standby system Please check the manual and other documentation gt lt E5 01084240 gt lt
437. over and confirm that the battery is installed properly b Connecting the Battery Connectors Align the connector mounted in the case with battery connector pin and insert it Connector Battery Connector Stay CONFIGURATION SYSTEM TRACKING CABLE A CPU module Diagram 4 5 Connecting the Case Connector and Battery Connector Pin Lu wn gt 2 p FA Ed m Zz a W a S 2 lt ws a2 S ES Refer to the following manual for installation of Q7BAT batteries and SRAM card fi batteries applicable to CPU modules A L gt QCPU User s Manual Hardware Design Maintenance and Inspection 22 og eeeeeeeceaoeoe eee eeeeeeeeseeeeeeeeeeeeeeeeeeeeeees eee e ee ee 56 ZR 5 ZO ae rad Z v E S o 2 i 3 fe 4 2 Wiring 4 9 PROCEDURE FOR STARTING UP A REDUNDANT SYSTE M M ELSEG Q series 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 yA Redundant CPU eN Connector a Tracking cable Diagram 4 6 Connecting a Tracking Cable Connector Make sure to tighten the tracking cable connector fixing screws after connecting the tracking cable Tightenin
438. played on GX Developer 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 when a communication error occurs between GX Developer and the control system standby system CPU module When the time from when the online program change to the control system is completed until the online program change to the standby system starts falls outside the SD1710 setting range this function judges it as a communication error and abnormally completes the online program change SD1710 defaults to 90 seconds and can be set within the range 90 to 3600 seconds 5 6 Online Program Change for Redundancy 5 6 2 Program Change While CPU is Running D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries 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 z Table5 55 Special Relays For Online Program change Number Name Explanation 1 Turning this relay from OFF to ON enables manual system switching during online z program change redundant tracking After the manual system switching disable status is canceled the system automatically turns off SM1709 Ei Manual system switching disable 2 System switching due to any of the following cond
439. ple Before measures Mo X10 Yio i f SET Y10 H M10 X10 Y10 E 4 RST Y10 H After measures M1 i SET Y10 ii as VA Del SET Y10 b F PLS M1 q Delays y one scan from PLS M1 M11 RST Y10 M10 X10 Y10 Ht 1 PLS M11 q Delays RST Y10 by one is T scan from PLS M11 Diagram 7 18 Program Example when there is Response Output to External Input POINT Set Do tracking of Signal flow memory tracking setting at Tracking settings of Redundant parameter 2 Precautions regarding timer Pay attention to the following points regarding timer at the time of system switching 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 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 7 20 7 4 Precautions at System Switching Occurrence PROGRAMMING CAUTIONS MELSEC KE eries 3 When output output Y writing to buffer memory is performed from the timer Scan execution type program contact the timer goes into the abov
440. ppendix 2 Comparison of Qn H CPU and QnPRHCPU A Comparison of Qn H CPU and QnPRHCPU is shown in Table App 3 Table App 3 Comparison of Qn H CPU and QnPRHCPU Item QnPRHCPU QnHCPU Scan time is increased by the tracking time Inside device 48 k word setting time Perf S Ti rer aNCE oao ne 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 Modules which are not duplicated are mounted to MELECNET H remote I O station Number of System Maximum Number of Modules l l Configuration Mounted on Main Extension mountable modules on remote I O station 64 64 Slots Main base unit Extension base Base Unit modules per station unit 7 stages 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 App 5 Appendix 2 Comparison of Qn H CPU and QnPRHCPU APPENDICES MELSEC TE eries Table App 3 Comparison of Qn H CPU and QnPRHCPU Continuation Item QnPRHCPU QnHCPU lt lt First 5 digits of serial No is 09011 or earlier gt gt N A Modules for the expanded system are mounted to MELSECNETH H remote I O station Restrictions on Mounting Modules on Remote I O Stations FROM TO instructions and intelligent function module devices U _ GL are inapplicable
441. pping 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 M eLS 26 Fel ceries 8 3 9 Tracking Cable Replacement 1 Tracking Cable Replacement ai The tacking cable cannot be replaced while both systems are running i O After powering off the standby system or keeping the standby system CPU module reset replace the tracking cable The standby system can be powered off or reset while the redundant system is running E Z0 Control system Standby system Fave je iea a8 w a q S 0 Tracking cable Z 6 Replace the tracking cable after powering F off the standby system or while keeping z the standby system CPU module reset Diagram 8 35 System where Tracking Cable Replacement z woe E an W D gt N 5a 36 Ze DOG az Zr W D gt wn Zv aon ZO ae W Ww eZ o o 56 ee ao o e o zZ O O ol w l D 2 O hA 8
442. quested 6014 to 7FFy A01 to BFF Data received 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 35 For the I O signal is X Y80 to X Y9F X83 X9F 7 o 4 FROMP H8 H600 DO K1 J Reads the number of receive data MOVP Do Zo J Stores the number of read data to index register Z0 TFROMP H8 H601 D1 KOZO Reads the receive data for the 5 number of receive data X30 X9F ia _ Reads the receive error code 15 l 14 LFROMP H8 H258 D8000 K1 J Check the error description and take corrective action according to the error code stored in D8000 X83 22 H Y81 Turns ON the read completion signal X60 24 H Y8E J Turns LED OFF and clears error code Diagram App 35 Program Example Appendix 6 10 BIDIN Instruction APPENDICES M ELSEG seres Appendix 7 Cautions on Communications Made via Module on 1 MC protocol frames available for communications 2 Extension Base Unit Use QnA compatible 2C 3C 4C frame QnA compatible 3E frame or 4E frame for the access MC protocol commands available for communications Table App 48 shows whether each access target can be specified for each MC protocol command or not when communications are made via a module on an extension base unit Table App 48 Applicability of connection destination specification of each command f
443. r Dialog Box Displayed on GX Developer 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 39 appears on GX Developer after the system switching repeat the operation mode change E MELSOFT application Operation mode separates backup are switched or the System switching control standby system is running cannot execute this Function BD Pease execute t again a switch lt ES 01084246 gt Diagram 5 39 Error Dialog Box Displayed on GX Developer When the operation mode change request is issued to the CPU module in the debug mode If the error dialog box Diagram 5 40 appears cancel Debug Mode in the redundancy parameters lt Section 5 1 3 MELSOFT series GX Developer JL Cannot execute this function when the PLC status is debug mode Diagram 5 40 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 41 appears on GX Developer cancel the specified control system CPU error and change the operating mode E MELSOFT application Cannot communicate with PLC For one of the Following reasons Communications timeout Cable error Specified transmission speed not supported for connected PLC Monitor condition set status is read by devi
444. r Station Station No 0 Standby Station Station No 1 System A Control System A IG Communication not possible l __ Tracking cable J X CC Link Remote I O station station No 2 System B Standby System nooo ooo000 J CoOU Ne oe ogag 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 M als 26 fel ceries c When System Switching is Manually Carried Out When system switching is manually carried out the new control system takes over the control of the redundant system S Y However the new standby system master station does not switch to the standby z mas
445. r Supply Module POWER LED After turning ON power supplies of the power supply modules of the main base units and extension base units in systems A and B check that POWER LED is turned ON green POWER LED ON green NU Or POWER Power supply module Diagram 4 10 Confirm that the POWER LED of power supply module is ON 1 The LED turns on on either system in the debug mode 4 12 4 3 Module Initial Settings PROCEDURE FOR STARTING UP A REDUNDANT SMELL M IES 26 FY aries 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 OVERVIEW 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 mowr SYSTEMA CONTROL seta SYSTEME SYSTEM B CONFIGURATION SYSTEM Refer to the following manual for details on the CPU module LED L gt QCPU User s Manual Hardware Design Maintenance and Inspection TRACKING CABLE 4 6 Starting up Connecting GX Developer A 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 Refe
446. r System Switching Instruction Execution Systems did not switch Is the BACKUP LED lit Green Red Backup Mode Turn off debug mode redundancy Amber Separate Mode parameters and change to backup mode Is the SYSTEM A B LED lit YES Reconfirm the connection status of the tracking cable for both systems Reconnect 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 System B For system B if a cable has been disconnected during normal operation the LED will flash until B system s connector is reconnected Is the standby system s power turned ON NO Turn ON the standby system power 4 Cancel the standby system s CPU module reset 4 Has the standby system s CPU module reset been canceled 1 8 1 Troubleshooting Flow 8 1 6 When System Switching has failed TROUBLESHOOTING MELSEC TE eries 1 a ed Ww gt Is the standby system CPU module ERR LED flashing Connect GX Developer to the standby 6 system CPU module use the System E Monitor PLC diagnostics to confirm g the problem area and resolve the a 2 problem BZ cas Restart the standby system cycle the standby system power or reset the standby system CPU module F 5 Yy 4 2 z O For the standby s
447. r module is switched to new control system master module and inherits the PROFIBUS communications 2 Operation at system switching 5 F The PROFIBUS DP master modules switch each system on the following cases g e When the PROFIBUS DP master module detects a fault ah wn e When a communication failure with DP Slaves is detected as Station No 0 A Control system Standby system a JNE 0 An error has Z been detected z fe Bus terminator Tracking cable Bus terminator x lt 3 r55 om ge selec eelee sales reg oe selec leelsaleeles aH DP Slave DP Slave Lu D gt wn Control Standby z 2 system system ge az New standby New control fee ime system system g i a 7 alld a ii Ji 7 H 5 E N as z5 Continues zg Tracking cable communications Sg Ae lu Ww ew Zz Bus terminator Bus terminator g i AAAH 5 OU i E EA FEJ EEFE EREE 8888188888818818 o oojoojoojoojoojoojaa 35 55 35 35 23 35 83 z DP Slave DP Slave Diagram 6 33 Operation of the PROFIBUS DP Master Module at System Switching 95 ao o z o O 35 if a O aa 6 2 Redundant System Network Overview 6 42 6 2 6 PROFIBUS DP 6 REDUNDANT SYSTEM NETWORKS 3 4 5 6 MELSEC TE cries 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
448. r some instructions are different Low speed Execution Type aera NIA Applicable Program Status Latch N A Applicable Program Trace N A Applicable Simulati ie Applicabl imulation icable Debug Substituted with GX Simulator RE is Function Sequence N A Zz Step Program gt Substituted with GX Simulator Applicable Execution SFC Program N A 3 Refer to the following manual for L3 QCPU User s Manual Hardware Settings Maintenance and Inspection Table App 2 Instructions Inapplicable for QNPRHCPU Instruction 4 Instruction R 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 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 Read From Remote I O Station Special Function RFRF PWM Pulse Width Modulation Module Write To Remote I O Station Special Function RTOP MTR Matrix Input Module Appendix 1 Comparison of Q4ARCPU and QnPRHCPU App 4 APPENDICES MELSEC Le ceries A
449. r supply modules slim type power supply module Power supply module and redundant power supply module Generic term for the Q6BAT Q7BAT and Q8BAT CPU module batteries and Battery Q2MEM BAT SRAM card battery SRAM card Abbreviation for the Q2MEM 1MBS and Q2MEM 2MBS SRAM card Flash card Generic term for the Q2MEM 2MBF and Q2MEM 4MBF Flash card ATA card Generic term for the Q2MEM 8MBA Q2MEM 16MBA and Q2MEM 32MBA ATA card Memory card Generic term for the SRAM card Flash card and ATA card A 21 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 he 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 fe switching The system that has switched to standby system from control system after system New standby system eee switching The slot that is located on the right s
450. r to Section 8 2 for the error resetting method PROGRAMMING CAUTIONS o e o zZ e O ol w l D 2 O hA 8 3 Replacing Module in Redundant System 8 42 8 3 4 I O Module Replacement Procedure 8 TROUBLESHOOTING 8 43 MELSEC TA eries 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 ooo000 nono nooo ooo000 CEE here IE coaie gl A z a aa I ooo Nexo NEN exo Nicaea Tracking cable ay Replace after using GX Developer to GX Developer switch over to the standby system Diagram 8 29 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 Control system
451. r to the following manual for applicable cables L3 QCPU User s Manual Hardware Design Maintenance and Inspection Lu wn gt 2 p FA Ed m Zz a W a S 2 lt ws a2 S EG REDUNDANT SYSTEM FUNCTIONS USB Cable REDUNDANT SYSTEM NETWORKS Personal Computer GX Developer Diagram 4 11 Connecting GX Developer and System A CPU Module PROGRAMMING CAUTIONS TROUBLESHOOTING 4 5 Confirming System A System B 4 13 PROCEDURE FOR STARTING UP A REDUNDANT SSE M M ELSEG A series 4 7 Writing Parameters and Programs to CPU Write parameters and programs to the CPU modules one CPU module in the debug mode 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 lt gt PLC module Connecting interface juss PLC Connection Station No Host PLC type Q12PRH Target memory Program memory Device memory xl Title File selection Device data Program Common Local Execute Execute L gt Param Prog Select all Cancel all selections Close Password setup 3 Program MAIN Device comment Transfer setup C COMMENT f Parameter PLC Redundant Network Remote Remote operation Device memory MAIN Redundant operation Related functions
452. r tracking transfer F While communication is executed via according to the right table tracking cable Max 30 Tp Program Execution Time power off occurs in the standby system 9 1 Extension of Scan Time due to Tracking 9 2 Q PROCESSING TIME FOR REDUNDANT SYSTEMS 1 Tracking Data Preparation Time Tra Tracking data preparation time is calculated as shown below Tra 1 Tra1 Tra2 Tra3 Tra4 ms MELSEC TE eries Table9 2 Processing Times of Tra1 to Tra4 Tracking Data Preparation Time Table9 2 Tra1 to Tra4 Transfer Data Processing Time Shown in Transfer Data Processing Time ms Time Set Using Redundant Trat Signal Flow Memory 1 0 13x103 x Z Parameter Tracking Tra2 SFC Information SFC Program Execution Time 1 Fixed PIDINIT Instruction Execution 0 5 Fixed Time Tra3 PID Control Instructions S PIDINIT Instruction p 0 5 Fixed Execution Time Tra4 Device Data X1 X2 X3 1 1 X1 to X3 are calculated as follows Z Number of Program Steps 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
453. r 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 control system identification flag SM1519 However when mounting a network module on the main base unit or extension base unit create an interlock circuit as shown on the programs in Diagram App 20 and Diagram App 22 before executing the SP CONTSW instruction If battery error occurs in either system and device data cannot be held the operation cannot be guaranteed PROCESSING TIME FOR REDUNDANT SYSTEMS APPENDICES INDEX 1 When network module is not mounted The following program shows an operation when the previous control system starts with no network module mounted 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 Control system System A System B 2 o eE E
454. ram Boot file SFC 1 0 assignment PLC system PLCRAS Operational settings 1 0 assignment WDT Watchdog timer setting Error check WDT Watchdog timer setting Error check 2 WDT Setting 200 ms 10ms 2000ms y Carry out battery check WOT Setting ms 10ms 2000ms rie exoculion V Carty out fuse blown check I Carry out fuse blown check 5 monitoring time ms 10ms 2000ms VV Verify module M Verify module oO I I fe m Constant scanning 2 Q Operating mode when there is an error Operating mode when there is an error S nO Computation error Stop ines 2 Sms 2000 Computation error Expanded commandenor Stop x Expanded command error Fuse blown Stop Fuse blown Module verify error Stop l Module verify error Inteligent module program orog Breakdown history Intelligent module program execution error a Record in PLC RAM execution error w File access error EJ x A Record in the folowing history fie File access error a Memory card operation eror Stop z ESRA i Memory card operation error Oo External power supply OFF Stop x oe External power supply OFF 9 Histo No item 16 100 S Acknowledge XY assignment CDi Check End Cancel Acknowledge XY assignment Desak Check End Cancel x wn Ox Diagram 6 19 In the case of Redundant CPU Diagram 6 20 In the case of Remote I O Station u o 2041 AZA Different error time operation modes can be set to the Redundant CPU remote Obs TED master station a
455. rcuit so that the programmable controller is turned on first and then the external power supply If the external power supply is turned on first an accident may occur due to an incorrect output or malfunction For the operating status of each station after a communication failure refer to relevant manuals for the network Incorrect output or malfunction due to a communication failure may result in an accident When changing data of the running programmable controller from a peripheral connected to the CPU module or from a personal computer connected to an intelligent function module configure an interlock circuit in the sequence program to ensure that the entire system will always operate safely For program modification and operating status change read relevant manuals carefully and ensure the safety before operation Especially in the case of a control from an external device to a remote programmable controller immediate action cannot be taken for a problem on the programmable controller due to a communication failure To prevent this configure an interlock circuit in the sequence program and determine corrective actions to be taken between the external device and CPU module in case of a communication failure CAUTION Do not install the control lines or communication cables together with the main circuit lines or power cables Keep a distance of 100mm 3 94 inches or more between them Failure to do so may result in malfunc
456. re not duplicated are mounted to MELECNET H remote I O station Number of mountable modules on remote O station 64 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 58 Modules main base unit extension base unit 7 stages Q4ARCPU repeat mode results in program priority mode on QNPRHCPU App Appendix 1 Comparison of Q4ARCPU and QnPRHCPU APPENDICES MELSEC TE eries 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 system are mounted to MELSECNET H remote I O station Restrictions on Mounting Modules on Remote I O Stations FROM TO instructions and intelligent function PROCESSING TIME FOR REDUNDANT SYSTEMS module devices U _ G _ are inapplicable Use REMFR REMTO for accessing Or in GX Configurator configure the settings for intelligent 2 APPENDICES function modules on remote I O stations The following modules cannot be mounted to remote I O stations CC Link IE Controller Network module MELSECNET H module interrupt module Web server module MES interface module PROFIBUS DP master module PROFIBUS DP slave module PROFIBUS DP interface module DeviceNet
457. rea Address 904 130p The mode No after switching 00014 to 0007 OOFFy is written to this area b15 to bO Buffer memory address 904 1304 Default 0000 a 00014 MC protocol Format 1 00024 MC protocol Format 2 00034 MC protocol Format 3 00044 MC protocol Format 4 00054 MC protocol Format 5 00064 Nonprocedural protocol 00071 Bidirectional protocol OOFFy GX Developer connection 1 1 When specifying GX Developer connection mode in Switch setting of GX Developer specify 004 to the communication protocol b Transmission specification area after switching Address 914 131p 1 Specify the transmission specification after mode switching i 2 Write 00004 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 b15 b14tob8 b7 b6 b5 b4 b3 b2 bi b0 1 0OHto OFy 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 CH1 side 1 00 to OFy 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 CH2 side ry _ i Setting Bit position Description OFF 0 ON 1 Operation setting Independent Linked Dat
458. registered in the failure history a b Cautions 1 When the corresponding error code is stored in SD50 and error clear is z9 O performed the last digit of the code No will be ignored ZE az When multiple errors of which codes are different in the last digit only occur ara the errors can be simultaneously cleared Example a If errors that correspond to error codes 2100 and 2101 occur both of them E will be simultaneously cleared when either one is cleared 7 Zn In the case of errors that correspond to error codes 2100 and 2111 both of 5 them will not be simultaneously cleared even when either one is cleared RE ez 2 If an error has occurred due to a problem other than that of the CPU module it will not be removed even when clearing the error is attempted using SM50 and SD50 Example g The cause of the SP UNIT DOWN error cannot be removed by performing Zo error clear operation using SM50 and SD50 as the error could have E occurred in a base unit including extension cables intelligent function S module etc Remove the cause of the error by referring to the error code list o e 3 If the cause of the error is not removed after error clear has been performed the same error will be detected o zZ O O ol w l D 2 O hA 8 2 Error Clear 8 32 8 TROUBLESHOOTING 4 Error clear processing is performed by END processing MELSEC TE eries Therefore an error cannot be cleared unless
459. rm iJ DUTY K1 K3 SM420 DUTY instruction during SM1518 shutdown Diagram 7 5 Program That Executes DUTY Instruction on the Falling Edge of SM1518 7 1 Instructions Restricted in Use for Redundant System PROGRAMMING CAUTIONS MELSEC TE eries b Relevant Instructions PLS P Examples MOVP INCP etc SP C GP g ZP Q JP q Intelligent Function Module Dedicated Instructions OVERVIEW 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 selection 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 CONFIGURATION SYSTEM Table7 4 Refresh Items by COM and ZCOM Instructions and Whether They Can Be Selected or Not in Redundant System Instruction Selection in redundant Refresh item symbol system I O refresh O TRACKING CABLE Network module refresh x 1 COM Auto refresh of intelligent function module x 2 Auto refresh of CPU shared memory x General data processing O Network module refresh x l REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ZCOM Auto refresh of intelligent function module x 2 O Selectable x Not selectable 1 Tracking is not executed w
460. rnally so that the z q overall system safety can be ensured even in these cases z eeeeeeecea oes eoeoeeeeeeoeaeoeeeoeoeeoeeeaeseeeeeoeoeeeeeeoeoeeeeeeee ee x lt 3 woe E Tor Lu D gt N Zz 56 ZE DO A A vr W D gt N Zg om ZO ae W Lu ez o zZ o 56 z ao 0 zZ O 35 iB a O aa 1 1 Redundant System Overview 1 5 1 OVERVIEW MELSEC TE cries 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 Data tracking Tracking cable Continue control using device data from Control system 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 sy
461. rol system CPU module a System switching using GX Developer When executing the system switching in the control system CPU module using GX Developer the system switching operation is done at END processing 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 control system CPU module The system switching request is issued to the control system CPU module by the redundant operation of GX Developer Redundant operation tga lean ice aM m En lt s Perei Satono Fist PLC ype OPRA Operaten med Backwpnode Calculating Stopping calculation System A System B System A System B Control Standby System System PI E z 1 1 i i E i i i g ajme i i 1 a i D RUN Control St tb Execute program system landby Tracking cable programi sy system UN 1 Stop program System switching operation Vv i 1 s x Execute system System switching IS by GX E i C i 1 i i on the control system Developer Syst GX Developer y END pa rate End calculation Begin calculating 9
462. rom request source Function 073 Target Command name sys Device memory Intelligent function module Batch read Connection destination specification ntrol Standby No system Ck System A tem system specification O O O O O Batch write Random read Test Random write Monitor data registration Monitor Multiple block batch read Multiple block batch write Batch read Batch write Programmable controller CPU File App 55 Remote RUN Remote STOP Remote PAUSE Remote latch clear Remote RESET CPU model name read Directory file information read XJOJOJO JOJO JOJO JO IO JO x x O JO JO X1OJO JO JOJO JO JOJO JO JO x x JOJO JO X1OJO JO JOJO JO JOJO JO JO x x JOJO JO Directory file information search x x x New file creation File deletion File copy File attribute change File creation data change File open File read File write File close For details of each command refer to the following manual x xX x x x x x x xK XIXIXIXIXIXIXIXIX XIXIXIXI XIXIXIXIX OJOJOJOJO JOJO JOJO O JOJOJOJO JOJO JO JOJO JO JOJO JO JOJO JO OJOJOJO JO JOJO JOJO O JOJOJO JO JOJO JO JOJO JO JOJO JO JOJO JO Remark eeeaeeeoeeeaoseeaoeoeseeeaeoeeeeeeoeeeaoeeoeaeoseeeeeeeaoeeeeaeaeeaeaoeeee C7 MELSEC Q L MELSEC Communication Protocol Reference Manual Appendix 7 Caution
463. rom the other station in order to continue control even when system switching occurs CC Link IE Controller Network EEES Send and receive Send and receive Send and receive Receive only Normal Normal station station Station No 4 Normal station Station No 3 o g Normal station ES a Control Control Standby system station system B o e Normal station Heist iets fol l l Tracking cable Diagram 6 7 Communication between Control System and Standby System Network Modules ata ial Uc 6 9 6 2 Redundant System Network Overview 6 2 1 CC Link IE Controller Network or MELSECNET H PLC to PLC network 6 REDUNDANT SYSTEM NETWORKS MELSEC KE eries
464. rs that detected errors can be checked using the special relay and special register below e SM62 Detection of annunciator ON SD63 Number of annunciators ON Perform error clear operation repeatedly until SM62 will be off or SD63 will be O then turn all annunciators from ON to OFF 8 TROUBLESHOOTING MELSEC TE eries 8 3 Replacing Module in Redundant System 8 3 1 CPU Module Replacement OVERVIEW 1 CPU Module Replacement The control system CPU module cannot be replaced while redundant systems are running When replacing the control system CPU module use GX Developer to switch its system to the standby system then start the replacement operation CPU module em CONFIGURATION SYSTEM Control syst a le Standby system E oo0000 ooo ooooo0 ooo F el Collsleoam E oolag Tracking cable Replace after using GX Developer to GX Developer switch over to the standby system Diagram 8 19 System where Control System CPU Module is Replaced TRACKING CABLE Replace the standby system CPU module after powering off the standby system The standby system can be powered off even while the redundant system is running
465. ry 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 Q12PRHCPU MODE BACKUP RUN CONTROL C_ ERR USER BAT BOOT ON red SYSTEMA SYSTEMB Standby system CPU module Q12PRHCPU Se MODE BACKUP RUN J CONTROL ERR SYSTEMA ON red USER SYSTEMB BAT BOOT Flashing red Diagram 5 87 LED Indications during Memory Copy Flashing red 2 When memory copy begins the MEM COPY EXE error code 6410 continuation 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 Q12PRHCPU MODE RUN Control system CPU module Q12PRHCPU MODE ERR USER BAT BOOT RUN USER BAT BOOT Flashing red ERR amp JIN
466. s 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 Sk z Fq ova z5 8a w Ww or 28 on an Lu n gt N Tsw g amp Tam Tre ms yn Q Tsw System Switching time 3 f Trc Reflection time for tracking data using the standby system lt CPU module Tam CC Link IE Controller Network MELSECNET H CC Link PROFIBUS DP automatic refresh time T am Refer to the manual for the network module being used A a When the extension base unit is connected S e Signal flow memory is not tracking transferred 31 5ms e 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 e Signal flow memory is tracking transferred 1 5ms System A System B Control Standby Run program system system System switching Detect cause of system switching request System switching processing time 21ms System switching time Tsw Execute Tracking transfer process Trc CC Link IE Controller Network MELSECNET H CC Link PROFIBUS DP automatic refresh time Ta m Standby o system Control Run program system b Diagram 9 1 Sy
467. s Instruction Classification Instruction Symbol Disable Interrupt DI Program Execution Control Enable Interrupt El Interrupt Disable Enable Setting IMASK File Register Block No Change RSET Change Instruction File Register File Set QDRSET Comment File Set QCDSET Application Instruction Timing Clock DUTY 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 When 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 SM1518 0 a DUTY K4 K3 SM420 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 After system switching perfo
468. s L gt Q Corresponding MELSECNET H Network System Reference Manual Remote I O network g 2 Diagnostics includes PLC diagnostics Ethernet diagnostics CC IE Control diagnostics o MELSECNET diagnostics and CC Link CC Link LT diagnostics E For details refer to each network manual 35 ES zZ 5 fe E A a 5 x E 4 5 PROCEDURE FOR STARTING UP A REDUNDANT SYSTE M M ELSEG Q series 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 ele c id latch eon gt A r arco Base unit module fixing projection Module Module installation lever Module fixing cutout Diagram 4 3 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 fixing screw if installed in a location exposed to strong vibration or impact In such cases tighten the module fixing screw within the
469. s 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 1 Tracking can be done in either backup mode or separate mode 2 Control system Standby system p E CSsl l ots E a O g Tracking cable During END processing default set data is tracking forwarded Diagram 5 47 Data Transfer by Tracking Function Following tracking data are set by default Internal devices SFC data ePID 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 lt gt Section 5 5 3 5 73 5 5 Tracking Function 5 5 1 Tracking Function Overview D REDUNDANT SYSTEM FUNCTIONS 2 3 MELSEC KE eries 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
470. s refer to the following manuals C gt GX Developer Version 8 Operating Manual L gt PX Developer Version 1 Operating Manual Programming Tool 5 97 5 6 Online Program Change for Redundancy 5 6 1 Writing to the CPU Module in STOP Status D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries d Access to files being written The files being written by GX Developer cannot be accessed by other GX Developer If you access the files being written the error dialog box in Diagram 5 62 will appear OVERVIEW E MELSOFT application i Processing is in progress from another peripheral device Please wait until the other processing is completed then execute again lt E5 010a4025 gt CONFIGURATION SYSTEM Diagram 5 62 Error Dialog Box Displayed on GX Developer 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 dialog box in Diagram 5 63 will appear TRACKING CABLE E MELSOFT application LD Processing is in progress From another peripheral device Please wait until the other processing is completed then execute again lt E5 010a4025 gt Diagram 5 63 Error Dialog Box Displayed on GX Developer Redo the PLC write after completion of the processing performed during access by other GX Developers REDUNDANT SYSTEM PROCEDURE FOR START
471. s again after the online program change is complete f When online program change cannot be executed to either control system or standby system In the following cases online program change cannot be executed to either control system or standby system REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol 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 Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le MELSOFT series GX Developer m N LD This will cancel the process because there is no communication with the standby system a Ze aon 28 Diagram 5 73 Error Dialog Box Displayed on GX Developer D m 2 Changing programs being accessed by the other GX Developer online The error dialog box Diagram 5 74 will appear if online program change is executed to programs being accessed by the other GX Developer o EE MELSOFT application Z Processing is in progress from another peripheral device Please wait until the other processing is completed then execute again y lt E5 010a4025 gt 6 OE lt a art ao Diagram 5 74 Error Dialog Box Displayed on GX Developer o z o 0 35 N Lu a O a
472. s control system is the system B r Jumps the processing to the END instruction by GOEND S executing the system switching instruction NET S RENE aS ap EEEE A a a TEE gy ge fas Sil a 4 User program 5 6 FEND Ends the main routine program ei 7 SM19519 r Stores the value of SD412 at subroutine program b LMOVP D412 D400 f execution to D400 DX101 _ Enables system switching when the CC Link SET SM1592 master module on extension base unit starts normally _ Executes the system switching instruction when the sP conTsw_ K1 M5004 f CC Link master module on extension base unit starts normally X101 Interlock signal CJ Pio1 H Jumps the processing to P101 with the system switching instruction 23 com Enables communications with GX Developer or others SM1519 Program which 24 Spee poo pane Calculates the subroutine waits 10 seconds program executing time for start up of the CC Link master Y lt D401 K10 WDT Resets the watchdog timer module on extension base _ Continues the jumps to P100 unit CJ P100 J until the SD401 value becomes 10 10 seconds P101 B 35 RET Ends the subroutine program Diagram App 22 A program example Appendix 5 Method for Starting up the Previous Control System App 30 APPENDICES 4 POINT i MELSEC TA eries If CC Link system master local modules are mounted on the main base unit system B cannot be started up as
473. s displayed in Table5 34 2 Watchdog timer error corresponds to WDT ERROR error code 5000 OR 5001 5 49 5 3 The System Switching Function 5 3 3 System Switching Execution Possibility D REDUNDANT SYSTEM FUNCTIONS MELSEC KE eries Table5 34 Operating Status and Details Operating Status Description Normal 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 Error The CPU module is in the RUN STOP and PAUSE status where a continuation error has occurred Stop Error The CPU module has stopped as a stop error has occurred Power Off The system power is OFF Resetting The CPU module is being reset At network fault detection A fault has been detected by at least one module of standby system network modules CC Link IE Controller Network module MELSECNET H module Ethernet module PROFIBUS DP master module Preparing for Tracking The communication is not made between the control system and standby system via tracking cable System Switching Request Timeout The system switching has not been completed as a data error occurred due to noise etc in the communication between the control system and standby system during system switching processing Executing System Switching System switching cannot be executed since the control system or standby system is executing system switching due to the
474. s not control system i E n gt o zg ou ZO gt ae ww eZ o zZ o Zz 6 o gt rt ao 0 zZ E O O T N w l fea O aa E 5 3 The System Switching Function 5 42 5 3 1 System Switching Method D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series 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 Switching Reasons for System Switching in Execution Timing Method Control System Stop error P System switching is executed when the reason for system Power off a Automatic System switching occurs Switchin g System switching request by network module System switching using GX System switching is executed at END processing of the scan Developer where the reason for system switching occurred 1 Manual Switchin 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 MELSEC Q L Programming Manual Common Instruction 5 43 5 3 The System Switching Function 5 3 2 System Switching Execution Timing D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries
475. s not start up within 3 seconds of the first one the STANDBY SYS DOWN error code 6300 continuation error will occur in the control system CPU module By disabling Check standby system malfunction at the standby System Monitor settings in the redundant parameter operation mode settings with GX Developer the control system will not detect the STANDBY SYS DOWN continuation error 5 5 5 1 Basic Concept of Redundant System 5 1 2 Determination of Control System and Standby System D REDUNDANT SYSTEM FUNCTIONS MELSEC KE eries b When system B starts up first Standby system Control system System A System B amp m m p y EE 2 show the powerup 3 B 7 E a a F g procedure i so eal A 0 8 ee z al tel Hq z all e H Tracking cable 2 Turn on the power for System A 1 Turn on the power for System B d Diagram 5 5 Control System and Standby System when System B Starts Up First A 6 2 When System A and Syst
476. s on Communications Made via Module on Extension Base Unit eeeeeoeeeeeaoseeeoeeseeeeeeoeeeoeeeeeeeeoseeeeeeeeoeeeoeeoeeeaoeoe eee APPENDICES MELSEC TE cries 3 System switching during communication made via a module on an extension base unit If system switching occurs during communication made via a module on an extension base unit by MC protocol or a dedicated instruction both the old and new control systems may not be able to respond and this may cause a communication timeout PROCESSING TIME FOR REDUNDANT SYSTEMS APPENDICES INDEX Appendix 7 Cautions on Communications Made via Module on Extension Base Unit App 56 INDEX A Applicable CAVICES eeccccccccccccccccccccccccccccccccces 2 13 Applicable software eocccccccccccccccccccccccccccccvcces 2 13 Applicable software packages seeeseeeeceeeceo000 2 17 Asynchronized tracking MOodesesesseseseeseseeses 000 5 93 Automatic system switching coooooooooooooo00000000000 535 System switching requested by the network module 000000000000000 0000000000000000000000000000000000000000000 5 36 System switching when a fault occurs in the control system cooooooooooooooo000000000000000000000000000000000 D35 Automatically transferred special registers se se 9 5 81 Automatically transferred special relays ssessese s 5 80 B Backup MOE ecececccccccccccccccccccccccccccccccccccccces 5 O Basic concept of redundant system eseeseeseeseeseeee 5 1 Basic
477. s with a tracking cable The connection direction connectors of the tracking cable determines which one is system A or B C gt 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 lt s gt Section 5 1 2 same module name into the same slot Pe Install a module with the i wt af D System A System B Control System Standby System i A pE A QJ71PB92V Q38B AN J X QJ71E71 QJ61BT11N QJ71LP21 QJ71GP21 SX 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 1 If system A and system B are started up within three seconds of one another system A becomes the control system 2 1 System Configuration 2 SYSTEM CONFIGURATION MELSEGC KE eries 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 s
478. seeses 8 45 Procedure for Replacing Module mounted on the I O Station of Redundant Systemesessesses 8 48 Replacement of Modules Mounted to Extension Base Uniteressessescescesccscccccccscccccsccsecees 8 49 Tracking Cable Replacement sseeeeeeeeeeeeesecocecceceococecocoeococeceeoeooocccecoeosossceeoeosssseeee B 50 Replacement Procedures of Extension Cable e seeesesesesseseessescesseseceosecossscesosssoososessoe 8 52 9 1to9 8 9 1 Extension of Scan Time due to Tracking ooooooooooooooooo000000000000000000000000000000000000000000000000000000 0 S 2 9 2 System Switching Time 00ooooooooooooo00000000000000000000000000000000000000000000000000000000000000000000000000000 0 6 APPENDICES App 1 to App 56 Appendix 1 Appendix 2 Appendix 3 Comparison of Q4ARCPU and QnPRHCPU CO OCCOOOCOOO OOO OOOOH OOO OOOO OOOOO OOO OOO OOOOOO OOO OOOOOOE App 1 Comparison of Qn H CPU and QnPRHCPU COCO OOOCOOO OOO OOO OO OOO OOOO OOO OO OOO OOO OOOOO OOOO OOOOOCE App 5 Comparison of QnPHCPU and QnPRHCPU COCO OOOOO OOO OO OOO OOOO OOO OO OOOOOOOOOOO OOOO OOO OOOOOOOOE App 9 Appendix 4 Sample Programs when Using CC Link eeeesesssscecoococcococococccococososocooccococsoesesoooo ADD 13 Appendix 4 1 Appendix 4 2 Appendix 4 3 Appendix 4 4 Appendix 4 5 Appendix 5 Appendix 6 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 Appendix 7 INDEX Sample Progr
479. shing red Diagram 5 82 LED Indications during Memory Copy 3 When 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 4 When memory copy begins the PRG MEM CLEAR error code 6400 stop error will occur in the standby system CPU module 5 115 5 7 Memory Copy From Control System To Standby System D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries 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 S a Q12PRHCPU Q12PRHCPU z MODE MODE RUN RUN L ERR ERR USER USER BAT BAT BOOT BOOT 2 Flashing red r Diagram 5 83 LED Indications at Memory Copy Completion d nz gt Q 6 When memory copy is complete restart the standby system or reset the ay standby system CPU module It will operate as the standby system CPU module Then the BACKUP LED of the
480. sible The power supply of the standby system was turned off reset status User WDT error status PLC has a H W problem lt E5 010a4241 gt Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le Diagram 5 36 Error Dialog Box Displayed on GX Developer e When the communication with the standby system is disabled due to tracking cable disconnection Lu If the error dialog box Diagram 5 37 appears on GX Developer check 7 the tracking cable connection and change the operation mode Ea aX aon Ml MELSOFT application E s W Ww e The tracking cable has a communication problem ma J Please execute it again after confirming the state of the tracking cable lt E5 010a4242 gt o zZ 22 Diagram 5 37 Error Dialog Box Displayed on GX Developer 2 z ao o zZ fe 35 N Lu a 5 a E 5 4 Operation Mode Change Function 5 60 D REDUNDANT SYSTEM FUNCTIONS 5 61 MELSEC TA eries 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 38 appears on GX Developer specify the control system CPU module and make the operation mode change request MELSOFT series GX Developer LD Cannot execute this Function when the PLC is not control system Diagram 5 38 Erro
481. ssing time Table6 6 Error Detection Processing Time Transmission speed Error detection processing time 10Mbps 5ms 5Mbps 8ms 2 5Mbps 15ms 625kbps 50ms 156 kbps 400ms PROGRAMMING CAUTIONS TROUBLESHOOTING 6 2 Redundant System Network Overview 6 36 6 2 4 CC Link 6 REDUNDANT SYSTEM NETWORKS Ml ELSEG Q series 6 2 5 Serial Communication Modules Mount the serial communication module on 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 bidirectional protocol For MC protocol external devices can communicate with the specified system i e control system standby system system A or system B Refer to the following manual for MC protocol lt 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 37 6 2 Redundant System Network Overview 6 2 5 Serial Communication Modules 6 REDUNDANT SYSTEM NETWORKS M als 26 Fel series
482. standby system CPU module will turn on green S z Control system CPU module Standby system CPU module z 7 f a f ON green S Q12PRHCPU Q12PRHCPU MODE BACKUP NES MODE BACKUP RUN CONTROL RUN CONTROL AI ON green e a BAT BAT u BOOT BOOT iS f 2 LI ON red OFF we 22g Diagram 5 84 LED Indications during Standby System CPU Module Operation 5 Es Oza W anr ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING 5 7 Memory Copy From Control System To Standby System 5 116 D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series b Operations when executing Memory Copy The operation at memory copy execution is shown in Diagram 5 85 Specify memory copy Perform memory copy Control system Standby system Control system Standby system E Tracking cable Tracking cable 2 Begin copying to the standby system CPU QU Control system Standby system 1 Memory copy from GX Developer GX Developer GX Developer Memory copy completed eo N oer Tracking cable 3 Copyin
483. stem Switching Timing 1 This indicates the system switching processing time for the case where the signal flow memory is set to No tracking in Tracking settings of Redundant parameter 2 This is 0 ms when tracking processing is not complete 3 The maximum system switching time is shown 9 2 System Switching Time 9 6 Q PROCESSING TIME FOR REDUNDANT SYSTEMS 1 Tracking Data Reflection Time Trc The reflection time for tracking data is calculated as shown below Trc 1 Trc1 Trc2 Trc3 Trc4 ms MELSEC TA eries Table9 5 Processing Times of Tra1 to Tra4 Tracking data preparation time Processing time for transfer data shown in Tre1 to Trc4 Table9 5 Transfer Data Processing Time ms Setting time for redundant Tre1 Signal Flow Memory 140 13 x103 xZ parameter tracking settings Tre2 SFC Information SFC program execution time 1 Fixed PIDINIT instruction execution 0 5 Fixed time Tre3 PID Control Instructions z S PIDINIT instruction oo 0 5 Fixed execution time Trc4 Device Data X1 X2 X3 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 track
484. stem indicates the backup system within a redundant system Section 5 1 2 If an error occurs in the control system the standby system takes over the control of the redundant system 3 Refer to Section 2 3 for details of network modules compatible for redundant system 1 2 Features 1 OVERVIEW M eLS eG lA eries 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 5 E l 20 a fr O H Pe O N 5 one O Q Tracking cable WwW l a Extension cable amp 9 Q65WRB Z 3 E x g aE E ES ia o J I Li i i Wi D gt N Zn z a6 ZE DOG as ew Diagram 1 3 System Configuration when Connecting Extension Base Unit z N 1 For the precautions of the system configuration when connecting the exte
485. stency Check 5 Q SYSTEM PROCEDURE FOR STARTING UP A TRACKING CABLE CONFIGURATION OVERVIEW REDUNDANT SYSTEM ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series 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 1 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 Q25PRHCPU Q12PRHCPU move O mope CZ RUN RUN Control Standby system system A im g fz ISS a ian Al ol 8 H z al amp a g 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 a
486. system a ooo000 nooo oo0000 o0 eo NColsw 5 mN i E E g E fam cong Ta aa Tracking cable 1 MELSECNET H Remote I O network gt TRACKING CABLE Ee Remote I O station Remote I O station station No 2 station No 3 REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A Multiplexed Remote Master Station station No 0 Control _ Standby Standby _ Control system System system System a Multiplexed Remote Sub master Master Stop Station station No 1 station nooo oooooo 2 Send a system switching request 3 t a 3 Perform system switching o I jeje REDUNDANT SYSTEM FUNCTIONS T CAMIA Eo coag COCCI eo naned ez Tracking cable 1 Communication not possible MELSECNET H Remote I O network gt Fi l
487. system configuration consistency check 5 21 Both systems operations after system switching CO COCOOO OOO OOOO OOO OOOO OOO OOO OOOO OOO OOOO OOOO OOOO OOO OOOOOOOOCE 5 51 C Canceling the debug MOE eeccccccccccccccccccccccces 5 14 Card removal setting enable flag S M609 sessesse2 5 24 Cautions Cautions when connecting a tracking cable 3 2 Handling CAUTIONS ce eecececcccccccccccccccccccccccccccs AG Cautions when connecting a tracking cable sssssss 3 2 Changing from separate mode to backup mode CO COOCOOOO OO OOOO OOOOH OOO OOOO OOO OO OOO OOOO OOO OO OOOO OOOO OOCOOOEE 5 59 Changing from the backup mode to separate mode ooooooooooooooooo00000000000000000000000000000000000000000000 HHO Confirming backup MOE coccccccccccccccccccccccccece 5 4 Confirming SM1511 and SM1512 to identify system A and system B eoccocoocooooooooooooooooooooo000000000000000 5A Confirming system A system B eesesseseeseeeeee 4 13 5 4 Confirming that the power supply is ON eeeeeeseeee 4 12 Confirming the control system standby system Confirming the separate Mode sresseeceseeseesceseesee 5 11 Connecting a tracking cable ssesseseeseeseeeeeees 3 3 4 10 Connecting GX Developer oooooooooooooooo000000000000 4 3 Connecting the Q6BAT battery connectors ssessee 4 9 Consistency CHECK eccccccccccccccccccccccccccccccccccee 16 Basic system configuration consistency check File consistency CHECK eccccccccccccccccccccccccccsee 5 18 Memory card setting status consisten
488. system u Watchdog Timer Errors System System System System Control Standby Standby Standby Watchdog Timer Startup as control system System System System System Control Standby Standby Control p Hardware Failure Startup as control system v Automatic System System System System a E System Control Standby Standby Control a aie Power OFF Startup as control system A Switching System System System System Z z Control Standby Standby Control D L Reseting Startup as control system System System System System System Switching DIRE Control Standby Control Standby System switching will cause system B to Request by Network System System System System become control system Module 6 System Switching Control Standby Control Standby Startup as standby system San Manual Using GX Developer System System System System aE System System Switching b 95 4 N in g 9y Control Standby Control Standby T2 Switching System Switching Startup as standby system ue System System System System Instruction zZ E O fe ag if a 5 3 The System Switching Function 5 46 3 5 3 3 System Switching Execution Possibility D REDUNDANT SYSTEM FUNCTIONS MELSEC TA eries Table5 30 Operations When System Switching Cannot Be Executed Due to Tracking Cable Disconnection System Status After System 5 A Control System Before System Switching System Switching Operation After Tracking Cable witchi ae Switching Condition
489. t CPUs in both systems are 09102 or higher and GX Developer version is 8 58L or later In other combinations the number of mountable modules per system is 4 POINT If setting 5 or more at No of boards in module in CC Link network parameter of GX Developer version 8 55H or earlier the following error dialog box appears MELSOFT series GX Developer i The selected PLC type does not support five modules or more Please set the number of boards in module less than five In this case set 4 or less at No of boards in module 2 4 System Configuration Cautions 2 SYSTEM CONFIGURATION MELSEC KE eries 4 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 OVERVIEW N 5 Number of Slots Occupied by a Redundant CPU A redundant CPU occupies two slots Main base unit slot 0 is set as follows type redundant points 0 points The I O number for slot 1 in which modules are mounted is X YOu z O T 5 o Le Z Q SYSTEM
490. t Operation EE o Z fe E i a z 5 10 Redundant CPU Functions Restricted in Redundant System 5 134 z 5 10 2 Remote Operation for Redundant System D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries 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 5 102 will appear MELSOFT series GX Developer x W Cannot execute this function when the PLC is not control system Diagram 5 102 Error Dialog Box Displayed on GX Developer b In the separate mode or debug mode In the separate mode or debug mode remote reset can be executed for only the system specified in the Connection setup of GX Developer The operation status of the unspecified system does not change STOP STOP Control system Standby system Col 06 Stam o Tracking cable GX Developer Control STOP Standby stop Reset STOP Remote operation Connection interface Target PLC PLC status System type Operation PLC Reset Connection target information system system oo00 Ey oooooo USB lt gt PLCE module STOP Standby system
491. t 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 4 Station No Settings for the Network Module Set the station Nos for network modules mounted on system A and system B of a redundant system with consecutive numbers Example If station No 3 is set for system A network module system B network module can be set as station No 2 or station No 4 CC Link IE Controller Network System A System B mE E mao o o a A H ale o LS z f ial JE z Ss U S RHB M Hal aie B BE gt 8 Tracking cable Set station No 3 Set station No 2 or 4 Diagram 6 10 Station No settings for the network module 6 13 6 2 Redundant System Network Overview 6 2 1 CC Link IE Controller Network or MELSECNET H PLC to PLC network REDUNDANT SYSTEM NETWORKS MELSEC TE eries 5 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 gt
492. ta 2 data 3 By Run R R z program 1 un Waiting 1 un Waiting 2 5s END o Program enn o Program END J 0 ae Control system 2 3 Yz CPU module 4 LH k Send Send a a 4 Tracking 4 Tracking g processing 1 processing 2 Ea Receive Receive 6 o5 z ao Standby system 4 CPU module Adjust Tracking Adjust Tracking 2 data 1 data 2 S Diagram 5 54 Tracking Operation Timing When Program Execution Time lt Tracking Processing Time 5 z z 5 5 Tracking Function z 5 5 7 Tracking Mode 5 92 D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series 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 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 tracking time Scan time Prepare Tracking data 3 Prepare Tracking Prepare Tracking alaa data 1 data 2 Error occurrence Control system Run ve Run ds Run END END END CPU module program 1 0 program 2 0 program 3 J EPRS New Standby system 9 Non executed CPU module Send _ Send Send 4 Tracking 4 Tracking 4 Tracking processing 1 processing 2 processing 3 Receive Re
493. ta 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 Standby station Master station System A System B Control System Standby System lt _ Send and receive data 4 Receive data Power supply QnPRHCPU QJ61BT11N Power supply module QJ61BT11N module QnPRHCPU i Tracking cable CC Link Remote I O station Remote device station Intelligent device station Diagram 6 25 Control of and Data Communication with Remote Stations 6 31 6 2 Redundant System Network Overview 6 2 4 CC Link 6 REDUNDANT SYSTEM NETWORKS M als 26 fel ceries 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 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 OVERVIEW Master Station Station No 0 Standby Station Station No 1 CONFIGURATION SYSTEM System A Control System System B Standby System ma ooo onoono
494. tandby system is not actually controlling Therefore there will be no effect on the redundant system control if the standby system is powered off When powering the standby system OFF the STANDBY SYS DOWN error code 6300 continuation error will occur in the control system CPU module 1 Module mounted to the extension base unit The online module change hot swapping is applicable for a module mounted to the extension base unit However there are restrictions on the module where the online module change is applicable For modules 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 QCPU User s Manual Hardware Design Maintenance and Inspection 2 Module mounted on the MELSECNET H remote I O station The MELSECNET H remote I O station supports online module change If a module mounted on the MELSECNET H remote I O station has a failure the module can be replaced without stopping system control However the target module of online module change is restricted Refer to Section 2 4 4 for details Refer to the following manual for information on online change of the module mounted on the MELSECNET H remote I O station K7 Q Corresponding MELSECNET H Network System Reference Manual Remote I O network L gt User s Manual of the corresponding module 5 8 Online Module Change Hot Swapping D REDUNDANT SYSTEM FUNCTIONS
495. tch to Neutral Position Lu wn gt 2 p FA Ed m Zz a W a S 2 lt ws a2 S a 1 Power on one system within three seconds after powering on the other system 2 Set the reset switch of one CPU module to neutral position within three seconds after making the same settings for the other CPU module 3 The LED turns on on either system in the debug mode 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 REDUNDANT SYSTEM FUNCTIONS REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING 4 8 Restarting System A and System B 4 15 PROCEDURE FOR STARTING UP A REDUNDANT SYSTE M M ELSEG Q series 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 ERR OFF ON Flashing 14 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 C QCPU User s Manual
496. te auto refresh D REDUNDANT SYSTEM FUNCTIONS MELSEC KE eries m hA W gt 0 In Separate Mode pe l Control System Standby System During Normal During Normal During Sto During Sto RUN and During During Stop g x RUN and During During Stop 7 R Error Error Resume Error Resume Error lt Executes the Executes the qo Does not execute the program A Does not execute the program e program program 3 HZ O nO Reflects the Reflects the operation result of operation result of the control Molds the standby Holds system system W a ON OFF ON OFF S Executes it Executes it oO Z X O Does not execute the check Does not execute the check E F i Does not execute Executes the function Executes the function i ii function x 5 P R lt Executes the check on the specified CPU module only Executes only on specified CPU module w SE z Executes only on specified CPU module Executes only on specified CPU module S g a Ebe Input it Input it 5 Output it Does not output it Output it Does not output it 5 z2 Executes input Does not execute input a 2 a Executes output Does not execute output min Executes the function Dossat perior Executes the function eon perform output it output it ai E 2 Executes the function Executes the function a E Zv aon zo Executes auto refresh Does not execute auto refresh a rad Executes auto
497. te operation screen of GX Developer remote operation is performed for the control system and standby system 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 operation screen of GX Developer When Both systems A amp B is selected GX Developer executes remote operation in order of the standby system CPU module and control system CPU module RUN RUN Control system Standby system ol IColzm 5 Tracking cable GX Developer 5 133 5 10 Remote operation Connection target information Connection interface COMT lt gt PLC modue RUN RUN gt STOP Target PLC T Stationno Host PLC type G25PRH Control system Standby system PLC status RUN jz a g fz B B Bj 8 a f
498. tem 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 N lt OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE oO lt 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 4 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 EF Section 5 5 5 ES POINT 1 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 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM ol Lu wn gt wn Zz a a ae a W a o Z O O Z u 2 Make sure the tracking cable is connected to the system A and system B i CPU modules before powering on the either system aga
499. tem Power Switching eee RE System Switching ae Method Switching Condition Condition OFF gt ON System A System B System A System B Stop Error Other Than Control Standby Standby Control i Startup as control system Watchdog Timer Error System System System System Control Standby Standby Standby Watchdog Timer Error Startup as control system System System System System Control Standby Standby Control F Hardware Failure Startup as control system Automatic System System System System System Control Standby Standby Control hae Power OFF Startup as control system Switching System System System System Control Standby Standby Control Reseting Startup as control system System System System System System Switching Control Standby Control Standby Request by Network Startup as standby system System System System System Module System Switching Control Standby Control Standby Startup as standby system Manual Using GX Developer System System System System System System Switching by eid n Control Standby Control Standby Switching System Switching Startup as standby system System System System System Instruction 5 47 5 3 The System Switching Function 5 3 3 System Switching Execution Possibility D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries Table5 32 When System Switching Cannot Be Executed Due to Watchdog Timer Error of Standby System System Status After System Status Before System cae Control System er
500. tem Standby system bl fe z nooo Cousneolaz Tracking cable Tracking cable 1 Be sure that SM1596 SM1597 are OFF and store 3D1H in SD1595 2 Turn ON SM1595 3 Begin memory copy SM1596 ON 4 Control system Standby system Display devices Display devices Memory copy complete Tracking cable 4 Memory copy completed SM1596 OFF SM1597 ON SD1596 Status information Display devices Diagram 5 90 Operation When Memory Copy Is Executed c Memory Copy special relay and special register status Executing memory copy Completed 1 ON Memory copy to other system start SM1595 OFF flag Set ON OFF by the user Memory copy to other system status SM1 596 OF flag The system turns it ON OFF Memory copy to other system SM1597 OFF completion flag The system turns it ON Memory copy target I O No D1595 Set by the user
501. tem status flag SM1596 turns off and Memory copy to other system completion flag SM1597 turns on Check whether SM1596 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 When memory copy is normally completed SD1596 0 e When memory copy is abnormally completed SD1596 other than 0 error code 5 113 5 7 Memory Copy From Control System To Standby System D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries 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 Redundant operation Connection target information Redundant operation Connection target information Connection interface COM1 lt gt PLC module OVERVIEW Connection interface COM1 Target PLC Station no Host PLC type Q25PRH Target PLC PLC status RUN PLC status RUN System type Operation mode Backup mode System type Control system Operation mode Backup mode Remote operation Memory copy progress status Remote operation Memory copy progress status g C System switching aa C System switching Memory copy failure fa g C Change operation mode ha Change operation mode zi 2 Men cop Wenn eani a Diagram 5 77 Redundant Operation Screen Show
502. tem switching was previously executed by one factor Please confirm the system lt E5 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 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 Backup Mode Separate Mode System Switching by The following stop error will occur upon System Switching Not performed instruction execution OPERATION ERROR Instruction error code 4121 REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol The following error message will be displayed on The following error message will be displayed on the GX Developer that was used to perform the the GX Developer that was used to perform the system switching system switching System Switching W N gt N FA lt T fa 5 MELSOFT series GX Developer MELSOFT series GX Developer ft in o Z O O Z Le Using GX Developer 5 1 Cannot execute this Function when the PLC is not control system J Cannot execute this Function when the PLC i
503. ter 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 7 7 Make sure to switch the data link control from the standby master station to the g 5 master station using the new control system s program ie no Refer to Appendix 4 for program details Oo Master Station Standby Station Station No 0 Station No 1 Lu Control system Standby system a oE s z HE zZ x 6 Tracking cable CC Link j X y R lt p55 204 aza Remote I O station OS station No 2 oan ange Master Station Standby Station fa Station No 0 Station No 1 Control _ Standby Standby _ Control Eo system System system System 3 5 fe cea al ZE ij a J E a Zz 1 gt f vara gl F i ez Tracking cable CC Link Submit SP CONTSW instruction Remote I O station station No 2 W wn gt n j A Ed a Zz fa W a n X x e z E W zZ Diagram 6 28 Operation When System Switching Is Manually Carried Out PROGRAMMING CAUTIONS TROUBLESHOOTING 6 2 Redundant System Network Overview 6 34 6 2 4 CC Link 6 REDUNDANT SYSTEM NETWORKS 6 35 MELSEC TE eries 3 Programs for Switching the Standby Mast
504. the CONTROL LED is OFF to the RUN position and confirm that the RUN LED of CPU module 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 x5 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 4 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 PROCEDURE FOR STARTING UP A REDUNDANT Se M als 26 FY aries Running Control System System A CPU module Refer to Section 4 11 1 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 OVERVIEW 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 Restarting System A and System B Refer to Section
505. the B system starts normally L SP CONTSW K1 M5004 4 Executes the system switching instruction when the network module in the B system starts normally a To p401 H Jumps the processing to P101 with the system switching instruction 25 com Enables communications with GX Developer or others SM1519 26 E SD412 D400 D401 Y Calculates the subroutine Program which program executing time waits 10 seconds for the network Y lt D401 10 wot Resets the watchdog timer module startup in the system B _ Continues the jumps to P100 ou P100 J until the SD401 value becomes 10 10 seconds P101 X 37 RET Ends the subroutine program Diagram App 20 A program example App 29 Appendix 5 Method for Starting up the Previous Control System APPENDICES MELSEC TE eries b CC Link master module is mounted on the extension base unit System Configuration PROCESSING TIME FOR REDUNDANT SYSTEMS System A System B Tracking cable CC Link master modules Extension cab APPENDICES Diagram App 21 System configuration when CC Link master module is mounted on the extension base unit INDEX Program Example The I O number assigned to CC Link master module is from X100 to 11F 0 9M1919 T CALL P4100 Makes the subroutine program P100 execute me a when the previou
506. 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 eeee E E E E O E eeseoeeeoeaeaoeaeoeeoeaeeceeaeeeeeaeeaoes ee eee The consistency check will not be executed during the following e Memory copy from control system to standby system eeeeeeesceaeoe eevee eee ee 5 1 4 System Consistency Check E E E E E e eeeeeeceaoeeaeoeoeeeeeeaeeeeeeeeeseeeeoe ee D REDUNDANT SYSTEM FUNCTIONS M aL 26 fel ceries 1 File Consistency Check a Check points The file consistency check means checking the following files at system switching as shown in Table5 11 OVERVIEW Table5 11 Target Files and Check Contents Target Files Details Checks the parameters stored in the drive set as parameter valid drive PLC parameters redundant parameters network parameters and the intelligent function module parameters set with GX Configurator Checks the remote password stored in the program memory Checks the program file set in the PLC parameters program settings The password set in th
507. the g tracking cable ao been connected to the NO BZ control system and standby gt Power off the standby system A 8 system CPU modules Connecting the tracking cable to the control YES system and standby system CPU modules Ww lt Section 3 3 a 0 y z 6 Power on the standby system W x Is the SYSTEM A B i z LED lit EOE Wee E TE De Is the tracking cable Secure the tracking cable connector connector secured to the to the CPU module with screws CPU module with gt Section 3 3 screws a D gt wn 3g Is the SYSTEM A B Z 5 LED lit mS ew Power off the standby system Y Completed W 5 Disconnecting the tracking cable from A the control system and standby system Br CPU modules gt Section 3 3 3 A ZO ae W Ww eZ Are there bent pins YES on the tracking cable connector 9 zZ o g OE Connecting the tracking cable Q2 connector to the control system and 20 standby system CPU modules F Section 3 3 8 Y 2 1 2 fe x n a 4 8 1 Troubleshooting Flow 8 8 8 1 3 When the SYSTEM A B LED is flashing 8 TROUBLESHOOTING Power on the standby system Is the SYSTEM A B LED lit Replacing the tracking cable LF Section 8 3 9 Reset the errors of the control system and standby system CPU modules IL Section 8 2 Clear the control system CPU module errors gt gt Section 8 2 Completed Is the SYSTEM
508. the module to prevent foreign matter such as wire chips from entering the module during wiring Do not remove the film during wiring Remove it for heat dissipation before system operation Mitsubishi programmable controllers must be installed in control panels Connect the main power supply to the power supply module in the control panel through a relay terminal block Wiring and replacement of a power supply module must be performed by maintenance personnel who is familiar with protection against electric shock For wiring methods refer to the QCPU User s Manual Hardware Design Maintenance and Inspection Startup and Maintenance Precautions WARNING Do not touch any terminal while power is on Doing so will cause electric shock Correctly connect the battery connector Do not charge disassemble heat short circuit solder or throw the battery into the fire Doing so will cause the battery to produce heat explode or ignite resulting in injury and fire Shut off the external power supply for the system in all phases before cleaning the module or retightening the terminal screws or module fixing screws Failure to do so may result in electric shock Undertightening the terminal screws can cause short circuit or malfunction Overtightening can damage the screw and or module resulting in drop short circuit or malfunction Startup and Maintenance Precautions CAUTION Before performing online oper
509. the standby system has started normally 6 2 Redundant System Network Overview 6 2 4 CC Link 6 REDUNDANT SYSTEM NETWORKS MELSEC KE eries 7 Cautions a Station number setting Set CC Link master module station number so that station number 0 is assigned to system A master station and other than station number 0 standby master station is assigned to system B OVERVIEW b Tracking device setting Set a device that makes auto refresh setting to the CC Link master module on the extension base unit as a tracking device Do not set the link special relay SB and link special register SW as tracking transfer device to the CC Link master module mounted on the main base unit c When using CC Link When the CC Link master module is mounted on main base unit the redundant system cannot start with the previous control system 3 Appendix 5 CONFIGURATION SYSTEM d Parameters in the debug mode In the debug mode the CPU module uses the parameters for system A to operate Therefore the station set as system B in the network parameters becomes absent station disconnected station TRACKING CABLE 8 Output Holding Time of Remote Station at System Switching When system switching occurs the remote station output is held until system switching is completed The remote station cannot be controlled from when system switching occurs until it is completed Use the expression shown in Table6 5 to calculate t
510. the standby system power Set the CPU module s RESET L CLR switch to the neutral position REDUNDANT SYSTEM FUNCTIONS 1 REDUNDANT SYSTEM NETWORKS PROGRAMMING CAUTIONS o e o zZ O O ol w l D 2 O hA 8 1 Troubleshooting Flow 8 12 8 1 5 When System Switching has Occurred 8 TROUBLESHOOTING NO Is switch factor 16 NO G YES YES YES This is a hardware fault in the CPU module so please contact the nearest Mitsubishi represenative reseller or branch office and explain the fault symptoms MELSEC TE eries Connect GX Developer to the standby system CPU module and check for faulty behavior using the System Monitor PLC diagnostics Correct the fault 1 Monitor the SD1690 with GX Developer and check the network module that requested the system switching Correct the network fault Monitor the system switching cause using GX Developer PLC diagnostic error information and check for system switching instruction arguments Correct abnormal behavior as appropriate for the argument Confirm with the GX Developer which performed the system switching Diagram 8 7 Flow for the Case where System Switching Occurred 41 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 1
511. the station No is set to other than 0 the LINK PARA ERROR error code 3101 stop error 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 STANDBY The CPU module develops the CONTROL SYS DOWN SYSTEM error code 6310 stop error CONTROL s SYSTEM The CPU module ignores the CPU module in the debug SEPARATE MODE 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 oa a In the debug mode the CPU module uses the parameters for system A to operate Therefore the station set as system B in the network parameters becomes absent station disconnected station Check the system switching operation in the backup mode prior to the system operation because the system switching cannot be checked in the debug mode On the programming at system switching refer to CHAPTER 7 PROGRAMMING CAUTIONS 5 15 5 1 Basic Concept of Redundant System 5 1 3 Operation Mode D REDUNDANT SYSTEM FUNCTIONS M als 26 fel ceries 5 1 4
512. tion 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 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 D REDUNDANT SYSTEM FUNCTIONS MELSEC TE cries 5 Operation Mode The redundant system operates in the following three modes a 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 control and continues the system control b Separate mode c The separate mode is for maintenance without stopping control In the separate mode different programs can be run in the control system and standby system CPU modules While continuing the system control in the control system program of standby system can be corrected and operation of program can be checked by using the data tracked from the control system
513. tion due to noise When a device such as a lamp heater or solenoid valve is controlled through an output module a large current approximately ten times greater than normal may flow when the output is turned from off to on Take measures such as replacing the module with one having a sufficient current rating After the CPU module is powered on or is reset the time taken to enter the RUN status varies depending on the system configuration parameter settings and or program size Design circuits so that the entire system will always operate safely regardless of the time Installation Precautions CAUTION Use the programmable controller in an environment that meets the general specifications in the QCPU User s Manual Hardware Design Maintenance and Inspection Failure to do so may result in electric shock fire malfunction or damage to or deterioration of the product To mount the module while pressing the module mounting lever located in the lower part of the module fully insert the module fixing projection s into the hole s in the base unit and press the module until it snaps into place Incorrect mounting may cause malfunction failure or drop of the module When using the programmable controller in an environment of frequent vibrations fix the module with a screw Tighten the screw within the specified torque range Undertightening can cause drop of the screw short circuit or malfunction Overtighteni
514. tive 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 Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le 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 s A The tracking transfer range cannot be set by the user EA 6 Do not perform the tracking transfer to the link special relay SB and link special register SW 5 z used in the network module system since they are the data inherent to stations Fa 7 Refer to Section 7 3 for the processing to be performed when the annunciator is tracked Remark Sooo ooo ooo F o Please use the following settings when changing the internal device settings aon rA e Bit devices including timer retentive timer counter aie 05 Multiples of 16 of the beginning device number S Transfer range is set in 16 point units e Word device Set in 1 point units z eeeeeeceoeeceaceoaeceaeaeeaeeoeoeeeceoeeeceeoeseeceeeeaeoeaeeeaoeeeceaeae ea eae eee S f a 5 a 5 5 Tracking Function 7 5 5 3 Tracking Data 5 D REDUNDANT SYSTEM FUNCTIONS Mi ELSEG Q series 2 Changi
515. to E4 F1 to F3 and K1 to K11 are values used in Table9 3 9 1 Extension of Scan Time due to Tracking Q PROCESSING TIME FOR REDUNDANT SYSTEMS M eLS eG lA cries 9 Table9 3 Counting Value of D1 to D4 E1 to E4 F1 to F3 and K1 to K11 25 lt System A z z Counting Hog Content Number O x m Value Oxy Symbol mane D1 Number of Tracking Device Points outside of Index Register K1 0 09 x 10 73 D2 Number of Tracking Device Points for Index Register K2 0 15x 103 Number of Tracking Device Points for Standard RAM File D3 K3 0 09 x 10 Register 2 Number of Tracking Device Points for SRAM Card File 5 D4 K4 0 42 x 10 A Register Q lt E1 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 h K7 5x103 Register Number of Tracking Device Ranges for SRAM Card File E4 K8 5x103 Register is F1 Number of Blocks not Including File Register K9 1x103 F2 Number of Blocks Including Standard RAM File Register K10 25x 10 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 digits of serial No is 06081 or before 120 3 x G 3 x 10 QnPRHCPU whose first digits of serial No is 06082 or later 120 x 103 3 Gis the number of clusters of the specified file regist
516. to F31 are turned off TRACKING CABLE RST M100 After F2047 is turned off and FO to F31 are turned off M100 is turned off 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 in the new control system CPU module at system switching REDUNDANT SYSTEM FUNCTIONS zzzi Tracking is executed F10 F10 is turned on after system switching F11 F11 is turned on after system switching Diagram 7 14 Program That Turns on the Annunciators by the OUT Instruction after System Switching REDUNDANT SYSTEM NETWORKS z o a g OF o3 E ao TROUBLESHOOTING 7 3 Precautions for Using Annunciator F in Redundant System T 15 PROGRAMMING CAUTIONS T 16 MELSEC TE eries 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 2 Tracking is executed 0 Mo SMIDE SET F10 F10 is
517. to GX Developer is Z x the standby system communication is done with lt the other system the control system via the gt iS tracking cable GX Developer Communicate with the control system CPU module Select this option to communicate with the standby System A Control System System B Standby System system CPU module using GX Developer Standby system x ra te tie foe lt If system switching occurs communication is done i 2 E rw 2Z with the new standby system CPU module a 9 5 If the CPU module connected to GX Developer is 2 E 2 Standby i GX Developer Communicate with the standby system CPU module ina W the standby system communication is done with ono System System A Control System System B Standby System that CPU module ee ys REE Standby system A E al i If the CPU module connected to GX Developer is E the control system communication is done with the a other system the standby system via the tracking S A cable GX Developer 5a qZ AO ZE j System A Control S System B Standby Syst aS e Select this option to communicate with system A SE ee ee az d i Y CPU module using GX Developer If system switching occurs communication 6 continues with the new system A CPU module ener If the CPU module connected to GX Developer is GX Developer Communica E ystem eee system A communication is done with that CPU System A Control System System B Standby System a T ps i module
518. trol System To Standby System 5 120 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS 4 Error Occurrence During Memory Copy MELSEC TE eries If any of errors listed in Table5 59 occurs during memory copy the contents of standby system memory will be corrupted 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 Table5 59 Error Occurrence During Memory Copy Cause Memory Copy Using GX Developer The following error dialog box will appear Control system power OFF SLL SDE L application i Cannot communicate with the PLC Execute again after checking the connections with the PLC e Control system CPU reset lt E5 01808201 gt e Standby system power OFF gt Unable to communicate with PLC The following reasons may be responsible Ee a e ear eee TE reset status e Standby system CPU reset ser WDT error status PLC has a H W problem lt E5 010a4241 gt Memory Copy Using Special Relays and Special Registers 42414 will be stored in SD1596 of the control syst
519. trol system a 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 and Fixed Scan Execution Type Programs PROGRAMMING CAUTIONS M eLS 26 Fel series 4 Interrupt by the Internal Timer 128 to 131 When system switching occurs execution of interrupt is suspended until system switching is complete Also interrupt from the module mounted on the extension base unit cannot be made When system switching occurs the new control system CPU module starts counting the interrupt interval time from 0 OVERVIEW Therefore the fixed scan execution interval is increased T q as shown in Diagram 7 9 The maximum value for the extension time is T q when q a CONFIGURATION SYSTEM Control system il New standby system System switching activated Interrupt type o Program z Scan execution type a Program New standby system a a Control system TRACKING CABLE Standby system Begin system System Switching complete Interrupt type switching i Program t Scan execution type New control system nee ef y Program 7 Standby system Ni New control system REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A a Interrupt interval T System switching time a Period between st
520. troller 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 APPENDICES 2 W O signal Table App 40 List of I O Signal V O signal NAT Signal name Description CH1 side CH2 side Transmission normal Xn0 Xn7 ON Normal completion completion x EET g Transmission abnormal zZ 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 ON Module error occurred Watchdog timer error X n 1 F OFF Module being normally WDT error operated Yn0 Yn7 Transmission request ON Requesting transmission Appendix 6 Precautions for Using Serial Communication Module 3 Buffer memory Table App 41 List of Buffer Memory Buffer memory address Hexadecimal decimal Stored value CR LF output designation B7 183 15714 343 0 Do not send 1 Send Output head pointer designation B8 4 184 1581 344 0 No designation For user frame 1 to 100 Send from nth being transmitted Output count designation B9 185 1594 345 designation 0 No designation 1 to 100 Output n Output frame No designation A BA to 11D4 15A to 1BD4 maximum of 100 can be specified 186 to 285 346 to 445 0 No designation 1 or more Output fr
521. tting Defaut Check End Cancel Diagram App 2 Program Setting Screen Appendix 4 Sample Programs when Using CC Link App 16 Appendix 4 4 Parameter Settings APPENDICES LLL MELSE Ley series 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 a a E oan aa on a a om on aa Lio Diagram App 3 Tracking Setting Screen App 17 Appendix 4 Sample Programs when Using CC Link Appendix 4 4 Parameter Settings APPENDICES MELSEC TE eries 3 CC Link Network Parameter Settings a Example of CC Link Network Parameter Settings An example of CC Link network parameter settings is shown in Diagram App 4 Refer to b for the actual settings PROCESSING TIME FOR REDUNDANT SYSTEMS E Network parameters Setting the CC Link list No of boards in module 1 _y Boards Blank no setting 1 Operational setting APPENDICES Master station data link type All connect count Remote input R 8 e i T e o pol po R N R Po Remote reaister Rww Ver 2 Remote inputfF SSS Ver 2 Remote output F EE Ver 2 Remote register Rr E Ver 2 Remote registerfA INDEX Retry count Automatic reconnection station count Stand by master station No PLC down select
522. turned on at the second scan i Do SM1518 ON gt OFF after system switching M1 SM1518 4 iE y set F10 F11 is turned on at the second scan SM1518 ON gt OFF after system switching Diagram 7 15 Program That Turns on the Annunciators by the SET Instruction after System Switching 1 SM1518 is a contact that turns on in the new control at occurrence of system switching and remains ON for one scan 7 3 Precautions for Using Annunciator F in Redundant System PROGRAMMING CAUTIONS MELSEC TE eries 7 4 Precautions at System Switching Occurrence 1 Precautions regarding access to intelligent function module and external device Depending on timing of system switching occurrence such as turning power supply OFF tracking transfer processing may be discontinued and the device data may not be reflected to the new control system CPU module after switching systems In this case the 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 OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE PROCEDURE FOR STARTING UP A REDU
523. type extension base unit to the first extension stage BASE LAY ERROR error code 2012 or 2013 occurs e Properly connect the redundant type extension base unit and the main base unit 2 Only one redundant type extension base unit is y vy EXT CABLE ERR error code 2020 occurs 32 applicable per system 5 2 OD The main base units used in systems A and B Xq v BASE LAY ERROR error code 2012 occurs oo should be the same model zZ fe fe E A a 5 oO fe 5 1 Basic Concept of Redundant System 5 22 5 1 4 System Consistency Check D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series 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 Memory Card Type w ue system SRAM card Flash card ATA card are the same 1 An error occurs because 2 An error occurs because th the memory card setting memory card type is status is inconsistent different ATA Card Flash Card D SRAM 1Mbyte SRAM 1Mbyte MITSUBISHI MITSUBISHI Not installed Control system Standby system ae
524. ule 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 A Connect the network wiring to the network module 1 Connect the I O module Lu wn gt 2 p FA Ed m Zz a W a 5 lt ws az Ob a Module Initial Settings Refer to Section 4 3 1 Set the RUN STOP switch of the CPU module to the STOP position 2 Set the RESET L CLR switch of each CPU module to the reset switch neutral position 3 Make switch settings for the MELSECNET H module Checking that power supply of main base unit and extension base unit is ON 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 REDUNDANT SYSTEM FUNCTIONS Refer to Section 4 4 Power supply voltage RUN STOP switch position of system A system B CPU module STOP REDUNDANT SYSTEM NETWORKS RESET L CLR switch position of system A system B CPU module Reset switch neutral 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 Checking System A System B Refer to Section 4 5 Check system A and system B by the SYSTEM A SYSTEM
525. undant parameter in which Do not start with Debug mode is set into the CPU module and power on the system again or set the RESET L CLR switch of the CPU module to reset switch neutral position Then the system will start up in the operation mode other than debug mode ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING 5 1 Basic Concept of Redundant System 5 14 5 1 3 Operation Mode D REDUNDANT SYSTEM FUNCTIONS M ELSEG Q series b Precautions 1 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 e Memory copy from control system to standby system e Tracking i 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 1 Cannot execute this function when the PLC status is debug mode ae Diagram 5 10 Error Dialog Box Displayed on GX Developer Change the redundant parameter to cancel the debug mode oO a When mounting the MELSECNET H remote master station on the main base unit set the station No to 0 master station If
526. upply 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 OVERVIEW N z O T 5 o Le Z Q SYSTEM Make Redundant Power Make Redundant Power supply module redundant supply module redundant Lu System A System B Ed Control System Standby System z O g Lu S cae 38RB Lo Q Q38 Wee ags Tracking cable WEZ TF 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 ep c Module which can be mounted to main base unit or extension base unit 7 For the module which can be mounted to the main base unit or extension base 42 unit refer to Section 2 3 55 W D ew d Redundant System Operations Refer to Section 5 1 for redundant system operations ai D gt N POINT ae z Q The extension base unit cannot be connected to the main base unit where the RE Redundant CPU whose first 5 digits of serial No is 09011 or earlier is mounted SE If connected a stop error BASE LAY ERROR error code 2010 occurs
527. uring online program change e System power OFF e CPU module reset e Tracking cable connection or disconnection Executing any of the above operations may corrupt the contents of program memory 5 6 Online Program Change for Redundancy 5 6 2 Program Change While CPU is Running D REDUNDANT SYSTEM FUNCTIONS MELSEC TE cries 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 71 will appear on GX Developer OVERVIEW MELSOFT series GX Developer LD Write during RUN will be cancelled because FILE DIFF 6000 has occurred in the standby system Diagram 5 71 Error Dialog Box Displayed on GX Developer CONFIGURATION SYSTEM 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 72 will appear on GX Developer E MELSOFT application This peripheral device or another peripheral device are operating online change function J Please execute it again after it completed online change function lt ES 010a424c gt TRACKING CABLE Diagram 5 72 Error Dialog Box Displayed on GX Developer Access the program
528. urrent 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 Device memory including special relays and special registers Continues the instruction execution Takes over the current status since operation was not executed before operation mode change Takes over the current status With tracking setting Takes over the current status Takes over the current status Signal flow Without tracking setting Takes over the current status Clears Turns off and then flashing RUNT 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 ON d then ON BACKUP green and then ON green and then ON orange orange Other than RUN and BACKUP Takes over the current status Takes over the current status _ Input Continues execution Continues execution I O from to main base unit Output Continues execution Starts output I O from to extension base Input Continues execution Does not execute input unit Output Continues execution Does not execute output s Link to CPU Continues execution Continues execution CC
529. utral position 3 Make switch settings for the MELSECNET H module Checking that Power Supply of Main Base Unit and Extension Base Unit is ON 1 Check the following items and turn ON power supplies of the power supply modules of the l main base units and extension base units Wiring of power supply Power supply voltage RUN STOP switch position of the CPU module STOP RESET L CLR switch position of the CPU module Reset switch neutral 2 Check that POWER LEDs of the power supply modules of the main base unit and the extension base unit are turned ON green Connecting to the PC in which GX Developer is installed 1 Start up GX Developer in the GX Developer installed PC 2 Connect the PC in which GX Developer is installed to the CPU module Writing Parameters and Programs to CPU Write the parameters and programs created with GX Developer to the CPU module Refer to Section 4 1 Refer to Section 4 2 Refer to Section 4 3 Refer to Section 4 4 Refer to Section 4 6 Refer to Section 4 7 4 PROCEDURE FOR STARTING UP A REDUNDANT Se M als AG FY caries Restarting System Refer to Section 4 8 Power off the system and then power on again or set the RESET L CLR switch of the CPU module S to the RESET position and then set it to the reset switch neutral position i Error Check Refer to Section 4 9 Check if the ERR LED o
530. vailable 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 21 5 1 Basic Concept of Redundant System 5 1 4 System Consistency Check D REDUNDANT SYSTEM FUNCTIONS M als 26 fel 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 UNIT RESET L CLR switch is set to the neutral LAY DIFF error code 6030 or 6035 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 CONFIGURATION SYSTEM The following stop error will occur in the standby system CPU module only UNIT LAY DIFF error code 6030 or 6035 1 If the UNIT LAY DIFF error occurs in the standby system configure the both basic systems of th
531. wer Supply Replacement Procedure PROGRAMMING CAUTIONS o e o zZ O O ol w l D 2 O hA 8 3 Replacing Module in Redundant System 8 40 8 3 3 Redundant Power Supply Replacement Procedure 8 TROUBLESHOOTING MELSEC TE eries 8 3 4 I O Module Replacement Procedure 1 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 zy ca est iegim 7 Tracking cable Replace after turning OFF the standby system power GX Developer Diagram 8 26 I O Module Replacement System during Power OFF 2 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
532. wer 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 gt Tracking cable lt Diagram 1 14 Vertical Arrangement of Control System and Standby System 1 16 1 2 Features 2 SYSTEM CONFIGURATION M eLS 26 Fel series CHAPTER2 SYSTEM CONFIGURATION This chapter explains the redundant system configuration OVERVIEW 2 1 System Configuration N An example of redundant system configuration is illustrated in Diagram 2 1 Personal computer OPS z O T 5 o Le Z Q SYSTEM Ethernet communication with upper layer W a lt S o Z CC Link IE Controller Network communication with other stations 2 2 a QCPU QCPU Normal station Normal station z x p 2na DP Slave DP Slave m PROFIBUS DP 32 I O control aes o TE Tracking cable crew CC Link ane I O control communication with external systems E n Extension Rem
533. when using the SFC program in the backup Mode 58 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 z The PID control data is tracked when executing the PIDINIT and S PIDINIT z zZ instructions in the backup mode y c Special Relays Table5 46 shows the automatically transferred special relays Special relays are only transferred in Backup Mode 2 x p O a gt Table5 46 Automatically Transferred Special Relays iF a Kaz Number Name Number ETT a z 5 Startup watchdog timer for step transition 7 9 x a SM90 to SM99 i SM701 Number of output characters selection Be Do Emabled only when SFC program exists SM202 LED OFF command SM702 Search method 5 SM206 PAUSE enable coil SM703 Sort order SM210 Clock data set request SM710 CHK instruction priority ranking flag E SM213 Clock data read request SM715 El flag i SM250 Max loaded I O read SM722 BIN DBIN instruction error disenabling flag 2 N PID bumpless processing for complate 55 SM254 All stations refresh command SM774 oz derlvative YE Selection of link refresh processing during COM SM255 to SM257 MELSECNET H module 1 information SM775 instruction execution SM260 to SM262 MELSECNET H module 2 information SM776 Enable disable local device at CALL fi SM265 to SM267 MELSECNET H module 3 information SM777 Enable disable local device in interrupt program
534. whether the tracking function is enabled or not in order to perform the tracking Refer to Section 5 5 for the tracking function b Confirming the Separate Mode Confirm that the redundant system is running in the backup mode by checking the BACKUP LEDs of CPU modules Table5 6 Checking the BACKUP LED to Confirm the Separate Mode CPU Module LED LED Status Q12PRHCPU Control Standby MODE LED Name RUN System System USER ON ON BAT BACKUP poor amber amber Refer to the following manual for details on the CPU module LED L gt QCPU User s Manual Hardware Design Maintenance and Inspection 5 11 5 1 Basic Concept of Redundant System 5 1 3 Operation Mode D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries c Precautions 1 When the operation mode is changed with GX Developer while the redundant 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 sys
535. witch RST Mo the error completion device M10 is set to ON Diagram 5 29 Program That Does Not Execute System Switching Instruction Again in New Control System CPU Module REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A 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 5 7 wn executed Eo Zz e When the error completion device is ON System switching is not do DO executed a Cw W 12 gt wn Zg om ZO Be W Ww ez 1 Z o 56 ra ao 0 Z O E N 5 a z 5 3 The System Switching Function 5 40 Z 5 3 1 System Switching Method D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries 2 Reasons for system switching can be set as system switching instruction parameter M1000 MO _ _ SP CONTSW K1 M10 I 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
536. witching Occurs during Online Program Change 5 6 Online Program Change for Redundancy 5 102 5 6 2 Program Change While CPU is Running OVERVIEW CONFIGURATION SYSTEM TRACKING CABLE REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A ol Lu wn gt wn Zz a a rs 2D fa W a o Z O O Z Le REDUNDANT SYSTEM PROGRAMMING NETWORKS CAUTIONS TROUBLESHOOTING D REDUNDANT SYSTEM FUNCTIONS 5 103 b When SM1710 is ON M ELSEG seres When SM1710 is on if a system switching occurs old data will not be output because tracking is performed also during online program change Refer to Section 5 5 4 for tracking data settings System A CPU module System B CPU module Control system Standby system RI MO Mo Circuit before program change in C100 Y100 4 ladder mode during RUN Refresh to the network module MO 9 p Circuit is added to _ Y100 Y100 System A CPU module When M0 is set to ON Y100 is also ae ia set to ON Mo MO iyo y0 Set Y100 external output to ON m m Refresh to the network Due to tracking module MO Y100 will be N S set to ON MO MO 4 y100 Y100 H Perform system switching due to a stop error in the control CPU module Control system Standby System Standby system Control System System B CPU module s Y100 external output will be left ON because Y100 is
537. witching may not be performed depending on the timing when the control system and standby system detects the fault Example The following diagram shows the processes that take place when the redundant system is connected to the MELSECNET H 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 e In this case the CAN T SWITCH error code 6220 continuation error will occur in the control system CPU module System switching request Standby system Error detection Control system Other Station s system a a Leon 0E9 System A MELSECNET H 2 Cable severed System A and B are standalone 1 Cable severed QnPRH system only is standalone Diagram 5 25 System Switching Operation at Cable Disconnection 5 37 5 3 The System Switching Function 5 3 1 System Switching Method D REDUNDANT SYSTEM FUNCTIONS MELSEGC TE eries 2 Manual System Switching Manual system switching means the system switching that is done manually by the user while the system is running 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 cont
538. xX POINT The system switching has not been completed as a data error occurred due to noise etc in the communication between the control system and standby system during system switching processing System switching cannot be executed since the control system or standby system is executing system switching due to the previous system switching condition 1 Make sure to set CPU Operation Mode to STOP default on the details settings of the PLC 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 45 5 3 The System Switching Function 5 3 3 System Switching Execution Possibility D REDUNDANT SYSTEM FUNCTIONS MELSEC TE eries Table5 28 Operations When System Switching Cannot Be Executed Due to Standby System Power Off Resetting or Hardware Failure a System Status After Operation After B System Power z System System Status Before ar BENS Control System ae System Switching ON OFF or unresetting the CPU Switching hee Sy System Switching a waked Switching Condition Condition module RESET L CLR switch is set System A SystemB SystemA System B to the neutral position Stop Error Other Than Control Standby Control Standby z Startup as standby system e Watchdog Timer Error System System System System lt Control Standby Standby Standby o
539. y be experiencing iS hardware errors Y a g 1 CPU module Completed 2 amp 2 Basic base module fa 3 Network Module xz 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 9 represenative reseller or branch office and z explain the fault symptoms z o ge Diagram 8 3 Flow for the Case where the MODE LED is not On ES o e 1 Relevant to the redundant power supply module o zZ O O ol w l D 2 O hA 8 1 Troubleshooting Flow 8 4 8 1 1 Flow for the Case where the MODE LED is not ON 8 TROUBLESHOOTING 8 1 2 When the CPU Module BACKUP LED is ON Red M ELSEG sornes The following flow Diagram 8 4 is for the case where the BACKUP LED of the CPU module is on red while the redundant system is running The BACKUP LED is lit up solid red Is the standby system s power turned ON YES Clearing control system CPU Is the BACKUP LED lit up solid green NO Has standby Turn ON the standby system power module errors C Section 8 2 system s CPU module reset been canceled Cancel the standby system s CPU module reset Clearing control system CPU Is the BACKUP LED lit up solid green Is the standby system
540. y will be tracked This setting reduces the number of internal device points that can be tracked at a time by 16k words S POINT 1 Precautions when disabling signal flow memory from being tracked e Rise instruction PLS OP SP Even if the execution condition is changed from off to on during system switching the rise instruction will not be executed after system switching e Fall instruction LDF ANDF ORF MEF PLF If the execution condition is off during system switching the fall instruction will be executed after system switching 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 5 79 5 5 Tracking Function 5 5 3 Tracking Data D REDUNDANT SYSTEM FUNCTIONS MELSEC KE eries 2 Automatic Tracking Data Automatic tracking data is the data that the redundant CPU tracks regardless of the redundant parameter tracking settings 5 n m gt 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 g et SFC data is necessary for continuing the SFC program Ba SFC data is tracked
541. ystem has a power OFF reset NO or stop error occurred 1 2 2 amp Zaa woe Q Pag Is the BACKUP NO Amber Separate mode eE LED ON solid green YES Green Backup mode wn Check operation starting from a Use GX Developer to change the ZE minimum system and work your way running mode to backup mode QZ up For modules that are not eu functioning contact the nearest Mitsubishi represenative reseller or branch office and explain the fault 5 symptoms i 12 gt wn Zg aon ZO Be 1 The CPU module ERR LED is flashing when a stop error has occurred Ww 9 zZ o 56 z2 ao o e o zZ O O ol w l D 2 O hA 8 1 Troubleshooting Flow 8 16 8 1 6 When System Switching has failed TROUBLESHOOTING 2 as an operation error occurred from the control system s system switching instruction YES Confirm individual information SD16 for control system errors MELSEC TE cries Depending on the control system error code confirm below and resolve the fault 4100 Specify a value other than 0 for 4120 SP CONTSW Turn ON 4121 SM1592 For separate mode operation Change the program to respond to SP CONTSW instructions not from the standby system but from the control system NO Change the tracking cable Is SD16 8 YES NO Yy Wait for the memory copy from control system to standby system to complete NO 3 8 17 8 1
542. ystem 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 written device data from the control system CPU module to check whether system switching occurred or not REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A eee Specify the control system and write REDUNDANT SYSTEM FUNCTIONS device data ez Specify the control system and read the written device data NO Communication failure System switching occurred W wn gt wn j 5 Ed a Zz fa W a n X x e z E W zZ Can the data be read normally YES Communication normal Change the connection setup o Are the read device data is consistent with Z9 the written device data NO Inconsistent System switching occurred Rs 2 ra ao YES Match End zZ Diagram 6 41 Flowchart for Checking for System Switching with the Written Device Data S a 5 ao 6 5 Precautions for Writing Device Data from Other Station 6 54 6 REDUNDANT SYSTEM NETWORKS MELSEC TE eries 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 syste
543. ystem 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 1 When One of the Systems Starts Up Before the Other One 1 2 If either system A or system B starts up before the other one the system that starts up first will be the Control system and the other one will be the Standby system 3 When both CPU modules of the system A and system B are reset the system with the CPU module of which RESET L CLR switch is set to the neutral position first will be the Control system and the other one will be the Standby system a When system A starts up first Control system Standby system System A System B js el a pl il oe Tracking cable 1 2 show the powerup procedure nooo oo0000 ooo000 zi ieam 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 3 If the second system doe
544. ystems CPU Module and GOTs 6 3 4 When Connecting GOTs to a Ethernet 6 REDUNDANT SYSTEM NETWORKS M als 26 fel ceries 6 4 Precautions for Accessing Redundant CPU from Other Networks In a system using CC Link IE Controller Network MELSECNET H MELSECNET 10 or Ethernet use of GX Developer or MC protocol allows communication with a redundant CPU by specifying control system standby system System A or System B Note that when accessing a redundant CPU from another network network of different network No there are the following restrictions on the CPU modules that can be used as relay stations gt Table6 8 OVERVIEW Table6 8 CPU Modules Applicable to Relay Stations for Communication with Redundant CPU from Other Networks CONFIGURATION SYSTEM Serial No of CPU module 06051 or earlier 06052 or later Serial No of CPU module 6054 orearlier 605Zorlater System specification pe A specified system system A specified system system A B QO0JCPU QOOCPU Q01CPU Q02CPU CPU module Q02HCPU model name QO6HCPU Q12HCPU Q25HCPU Q12PHCPU Q25PHCPU TRACKING CABLE Applicable x Inapplicable REDUNDANT SYSTEM PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM FUNCTIONS ez W wn gt n j A Ed a Zz fa W a n X x e z E W zZ PROGRAMMING CAUTIONS TROUBLESHOOTING 6 4 Precautions for Accessing Redundant
545. zed Asynchronous to asynchronized LOE tracking mode Asynchronous tracking mode tracking mode STOP STOP 5 tracking mode PAUSE PAUSE Stop Error wn RUN Bo Stop Error he ee P PAUSE RE W gt Stop Error pam 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 E is changed to backup mode a E 3 When the special relay Device memory tracking during RUN write SM1710 is turned on to 22 execute tracking during online program change tracking during online program change is Z executed in the asynchronous tracking mode lt _ Section 5 6 2 Di o zZ o 56 z3 PL zZ fe fe E N 5 a 5 oO fe 5 5 Tracking Function 5 90 5 5 7 Tracking Mode D REDUNDANT SYSTEM FUNCTIONS Control system MELSEC TE eries 2 Synchronized Tracking Mode Run 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 C

QnPRHCPU User's Manual (Redundant System)

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