Page 3: Safety Precautions
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: " WARNING"...
Page 4 [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 circuit so that the programmable controller is turned on first and then the external power supply.
Page 5 [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.
Page 6 [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 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.
Page 7 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.
Page 8 [Startup and Maintenance Precautions] CAUTION Before performing online operations (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.
Page 9 [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...
Page 10: Conditions Of Use For The Product
PRODUCT in one or more of the Prohibited Applications, 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.
Page 11: Revisions
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...
Page 12 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.
Page 13: Table Of Contents
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.
Page 14 Starting up/Connecting GX Developer •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 - 13 Writing Parameters and Programs to CPU •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 - 14 Restarting System A and System B ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 - 15 Error Check •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 - 16 4.10 Confirming the Control System/Standby System ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 - 16 4.11 Running CPU Modules•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••...
Page 15 CHAPTER6 REDUNDANT SYSTEM NETWORKS 6 - 1 to 6 - 55 Communication with GX Developer and PX Developer ••••••••••••••••••••••••••••••••••••••••••••••••••••• 6 - 1 6.1.1 Communication Methods with GX Developer•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6 - 1 6.1.2 Confirming the Connection Target on GX Developer ••••••••••••••••••••••••••••••••••••••••••••••••• 6 - 3 6.1.3 Cautions on Access from GX Developer and PX Developer •••••••••••••••••••••••••••••••••••••••••...
Page 16 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 ••••••••••••••••••••••••••••••••••• 8 - 30 Error Clear••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••...
Page 17: About Manuals
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 Number Manual Name (Model Code) QCPU User's Manual (Hardware Design, Maintenance and Inspection) SH-080483ENG This manual provides the specifications of the CPU modules, power supply modules, base units, extension (13JR73) cables, memory cards and others.
Page 18 Related Manuals Manual Number Manual Name (Model Code) Q Corresponding Serial Communication Module User's Manual (Basic) This manual provides an overview of the module and describes the applicable system configuration, the SH-080006 specifications, the procedures prior to operations, the basic methods of communicating with the external device, (13JL86) maintenance and inspection, and the troubleshooting of the Q-Corresponding Serial Communication Module.
Page 19: How To Use This Manual
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 Explains the redundant system overview and system configuration 2) Chapter 3 Explains the tracking cable specifications, part names and...
Page 20: How This Manual Is Organized
HOW THIS MANUAL IS ORGANIZED Reference destination Chapter heading A reference destination or The index on the right side of the page reference manual is marked shows the chapter of the open page at a glance. Section title The section of the open page is shown at a glance.
Page 21 In addition, this manual provides the following explanations. POINT Explains the matters to be especially noted, the functions and others related to the description on that page. Remark Provides the reference destination related to the description on that page and the convenient information.
Page 22: Generic Terms And Abbreviations
Generic term for the Q02CPU, Q02HCPU, Q06HCPU, Q12HCPU and Q25HCPU Process CPU Generic term for the Q02PHCPU, Q06PHCPU, Q12PHCPU and Q25PHCPU Redundant CPU Generic term for the Q12PRHCPU and Q25PRHCPU Generic term for the Q00UJCPU, Q00UCPU, Q01UCPU, Q02UCPU, Q03UDCPU, Q04UDHCPU, Q06UDHCPU, Q10UDHCPU, Q13UDHCPU, Q20UDHCPU, Universal model QCPU...
Page 23 Generic Term/Abbreviation Description Extension base unit Generic term for the Q5 B, Q6 B, Q6 RB, and Q6 Slim type main base unit Another name for the Q3 Redundant power main base unit Another name for the Q3 Redundant power extension base Another name for the Q6 unit Redundant type extension base...
Page 24: Relevant Terms
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;...
Page 25: Chapter1 Overview
OVERVIEW 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, and others to QCPUs. (1) Specifications and handling of QCPUs, Power Supply Modules, Base Units, memory Cards, etc.
Page 26 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. Table1.1 List of user's manual of redundant CPU Maintenance Program Multi CPU Redundant Fundamentals System system Inspection...
Page 27 OVERVIEW Table1.2 List of programming manuals of redundant CPU Process Common PID control Structured MELSAP-L control Instructions Instructions Text Instruction QCPU (Q mode)/ QCPU (Q mode)/ QnPHCPU/ QCPU (Q mode) QnACPU QnACPU QnPRHCPU QCPU (Q mode)/ QCPU (Q mode) Programming Programming Programming Programming...
Page 28: Redundant System Overview
OVERVIEW 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 others, so that even if a module error occurs in one basic system, the other one continues the system control.
Page 29 OVERVIEW * 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.
Page 30: Features
OVERVIEW 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.
Page 31 OVERVIEW (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.
Page 32 OVERVIEW (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.
Page 33 OVERVIEW (b) MELSECNET/H Remote I/O Network MELSECNET/H remote I/O stations can continue the operation even when control/standby system switching occurs. ( Section 6.2.2) Multiplexed Remote Master Station Multiplexed Remote Sub-master Station Control system Standby system Tracking cable MELSECNET/H Remote I/O network Remote I/O Remote I/O Remote I/O...
Page 34 OVERVIEW (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 DP - Slave DP - Slave Control Standby...
Page 35 OVERVIEW (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. Section 5.6.1) Control system Standby system...
Page 36 OVERVIEW (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.
Page 37 OVERVIEW (7) Access to redundant system from host network When accessing to a redundant system, the host OPS can automatically identify and directly access to the control system, if it has been specified as destination in advance. Ethernet Control system Standby system Tracking cable Control and network...
Page 38 OVERVIEW (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. ( Section 2.4 (6)) The module can be replaced without stopping the system, when it fails.
Page 39 OVERVIEW Failed module Standby Control system system Set online module Tracking cable change (hot swapping) Cancel online module 2) Online module change (hot swapping) change (hot swapping) Replacement module 1) to 3) shows the online module GX Developer change procedure. Diagram 1.11 Online Module Change (Hot Swapping) of I/O Modules mounted on a Main Base Unit (10)System status can be monitored.
Page 40 OVERVIEW (11)Compact Redundant System The space of control panel can be saved, as Q series modules (other than the CPU module, redundant power supply module, and tracking cable) are applicable. (12)Flexible layout The layout can be changed flexibly because the main base unit is divided into two units for the control system and standby system.
Page 41: Chapter2 System Configuration
SYSTEM CONFIGURATION CHAPTER2 SYSTEM CONFIGURATION This chapter explains the redundant system configuration. 2.1 System Configuration An example of redundant system configuration is illustrated in Diagram 2.1. Personal computer Ethernet (communication with upper layer) CC-Link IE Controller Network (communication with other stations) QCPU QCPU (Normal station)
Page 42 Q38B QJ61BT11N Tracking cable QJ71LP21 QJ71GP21-SX Q12PRHCPU Q61P Diagram 2.2 Redundant System Configuration POINT The extension base unit cannot be connected to the main base unit where the Redundant CPU whose first 5 digits of serial No. is "09011" or earlier is mounted.
Page 43 SYSTEM CONFIGURATION (b) Backup of Power Supply Module The power supply module of each system can be backed up. By adding backup power supply modules to system A and system B, even if an error occurs in the power supply system connected to one power supply module, or if the power supply module fails, the other power supply module can continue the operation.
Page 44 SYSTEM CONFIGURATION (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 Tracking cable Diagram 2.4 Connection of Redundant System to Ethernet (b) Ethernet Modules applicable to Redundant System...
Page 45 SYSTEM CONFIGURATION (3) Communication via CC-Link IE Controller Network or MELSECNET/H PLC to PLC Network (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.
Page 46 SYSTEM CONFIGURATION Normal station Normal station Normal station Normal station MELSECNET/H (MELSECNET/10 Mode) PLC to PLC network (communication with other stations) Control station Normal station Normal station Normal station System B - System B - Standby System Standby System Tracking cable Pairing setting is required Pairing setting is required Diagram 2.5 Connection of Redundant System to MELSECNET/H PLC to PLC Network...
Page 47 SYSTEM CONFIGURATION (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.
Page 48 SYSTEM CONFIGURATION (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.
Page 49 SYSTEM CONFIGURATION (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. (b) CC-Link master module setting Set the CC-Link master modules as follows. 1) When mounting to the main base unit •...
Page 50 SYSTEM CONFIGURATION (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. 2) When using the QJ61BT11N whose first 5 digits of serial No.
Page 51 SYSTEM CONFIGURATION (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. (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.
Page 52: Peripheral Device Configuration
SYSTEM CONFIGURATION 2.2 Peripheral Device Configuration Redundant CPU Memory Card * RS-232 Cable Personal Computer (GX Developer, PX Developer, GX Simulator) * USB Cable * Memory Card * PC Card Adapter Diagram 2.9 Peripheral Device Configuration * 1: Do not format ATA cards for using other than GX Developer. 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.
Page 53: Applicable Devices And Software
Power supply module • Q63P • Q64P • Q64PN • Q63RP *2 *7 Redundant power supply module • Q64RP • Q12PRHCPU CPU module • Q25PRHCPU • QJ71GP21-SX *6 *8 CC-Link IE Controller Network module • QJ71GP21S-SX • QJ71LP21-25 • QJ71LP21S-25 •...
Page 54 SYSTEM CONFIGURATION (b) Modules that cannot be mounted to MELSECNET/H remote I/O stations Refer to the following manual for the modules that cannot be mounted to MELSECNET/H remote I/O stations. 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.
Page 55 SYSTEM CONFIGURATION (2) Confirming the serial No. and function version of the CPU module (a) On the rated plate The serial No. and function version of the CPU module can be confirmed on the rated plate. Serial No. (first 5 digits) function version Relevant regulation standards Diagram 2.10 Rated plate...
Page 56 SYSTEM CONFIGURATION (c) 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.
Page 57 SYSTEM CONFIGURATION (3) Available software packages (a) Available GX Developer and PX Developer versions Table2.2 shows GX Developer and PX Developer versions supporting redundant system. Table2.2 Available GX Developer and PX Developer versions Product Name Model Version *1 *3 GX Developer SW8D5C-GPPW-E Ver.8.17T or later *2 *4...
Page 58: System Configuration Cautions
SYSTEM CONFIGURATION 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.
Page 59 SYSTEM CONFIGURATION • 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. • MELSOFT products connectable to a module mounted on the extension base unit are GX Developer and PX Developer.
Page 60 SYSTEM CONFIGURATION (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 Limitation on the number of mountable Applicable Module Type modules per system...
Page 61 SYSTEM CONFIGURATION (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.
Page 62 SYSTEM CONFIGURATION (6) 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.
Page 63: Chapter3 Tracking Cable
TRACKING CABLE CHAPTER3 TRACKING CABLE This chapter provides the tracking cable specifications and part names, and explains connecting/disconnecting the cable to/from the CPU module. 3.1 Specifications The tracking cable specifications are shown in Table3.1. Table3.1 Tracking Cable Specifications Name Item QC10TR QC30TR Cable Length...
Page 64: Connecting And Disconnecting A Tracking Cable
TRACKING CABLE 3.3 Connecting and Disconnecting a Tracking Cable (1) Cautions when Connecting a Tracking Cable • Be careful not to step on the tracking cable. • When laying tracking cables, secure a minimum bending radius of 27.6 mm or more.
Page 65 TRACKING CABLE (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. (b) Hold the tracking cable connector, and align it with the CPU module TRACKING connector.
Page 66 TRACKING CABLE (3) Disconnecting a Tracking Cable (a) Loosen the connector fixing screws. Connector screws Flathead screwdriver Tracking cable 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. Redundant CPU TRACKING connector Connector...
Page 67: Chapter4 Procedure For Starting Up Aredundant System
PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM CHAPTER4 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM (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.
Page 68 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM Connecting to the PC in which GX Developer is Installed ...Refer to Section 4.6 Start up GX Developer in the GX Developer installed PC. Connect the PC in which GX Developer is installed to the system A CPU module. Writing Parameters and Programs to CPU ...Refer to Section 4.7...
Page 69 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM Running Control System (System A) CPU module ...Refer to Section 4.11 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."...
Page 70 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM (2) Procedure for starting up in debug mode 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. Start Mounting Modules ...Refer to...
Page 71 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM 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 to the RESET position and then set it to the reset switch neutral position. Error Check ...Refer to Section 4.9...
Page 72: Mounting Modules
PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM 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.
Page 73: Wiring
PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM 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 connection. Install the wiring to a network module by referring to the corresponding manual, as the wiring method differs according to model.
Page 74 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM POINT 1. 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-circuit due to loosening screws, use the solderless terminals with insulation sleeves of 0.8 mm (0.03 inch) or less.
Page 75 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM (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. (a) Confirming Battery Installation Status Open the CPU module bottom cover, and confirm that the battery is installed properly.
Page 76 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM (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.
Page 77 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM (4) Connecting extension cables When using the redundant type extension base unit, connect extension cables by the following procedures. System A connector System B connector Control system Standby system Tracking cable Extension cable Q65WRB Q68RB Q68RB...
Page 78: Module Initial Settings
PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM 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.
Page 79: Confirming System A/System B
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 Q12PRHCPU SYSTEM A MODE BACKUP CONTROL SYSTEM B ERR.
Page 80: Writing Parameters And Programs To Cpu
PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM 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"...
Page 81: Restarting System A And System B
PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM 4.8 Restarting System A and System B Power on system A and system B again, or set the reset switches of system A/system B CPU modules to neutral position, in order to restart the redundant system. (1) Powering supply ON again Power off system A and system B, and then simultaneously power on the both systems.
Page 82: 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) LED Name Normal Error Q12PRHCPU ERR. ON/Flashing MODE BACKUP CONTROL ERR.
Page 83 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM Memo 4.11 Running CPU Modules - 17...
Page 84: Chapter5 Redundant System Functions
REDUNDANT SYSTEM FUNCTIONS CHAPTER5 REDUNDANT SYSTEM FUNCTIONS This chapter explains the redundant system functions. 5.1 Basic Concept of Redundant System A redundant system consists of two basic systems, each of which includes a power supply module, CPU module, main base unit and network module. To configure a redundant system, connect the basic systems on which above modules are mounted with a tracking cable.
Page 85 REDUNDANT SYSTEM FUNCTIONS (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.
Page 86: Determination Of System A/System B
REDUNDANT SYSTEM FUNCTIONS 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 tracking cable, i.e., connectors.
Page 87 Identify system A and system B by checking the "SYSTEM A" and "SYSTEM B" LEDs of CPU modules. Table5.1 Identify system A and system B by checking the "SYSTEM A" and "SYSTEM B" LEDs CPU Module LED LED Statuses Q12PRHCPU LED Name System A System B MODE...
Page 88: Determination Of Control System And Standby System
REDUNDANT SYSTEM FUNCTIONS 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".
Page 89 REDUNDANT SYSTEM FUNCTIONS (b) When system B starts up first Standby system Control system System A System B 1), 2) show the powerup procedure. Tracking cable 2) Turn on the power for System A. 1) Turn on the power for System B. Diagram 5.5 Control System and Standby System when System B Starts Up First (2) When System A and System B Start Up Simultaneously * If system A and system B start up simultaneously, system A will be the "Control...
Page 90 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 LED Name MODE BACKUP...
Page 91 REDUNDANT SYSTEM FUNCTIONS (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.
Page 92: Operation Mode
REDUNDANT SYSTEM FUNCTIONS 5.1.3 Operation Mode The operation mode determines the redundant system operation methods. Following three operation modes are available. • Backup Mode • Separate Mode • 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.
Page 93 Confirm that the redundant system is running in the backup mode by checking the "BACKUP" LEDs of CPU modules. Table5.5 Checking the "BACKUP" LED to Confirm the Backup Mode CPU Module LED LED status Q12PRHCPU Control Standby LED Name MODE...
Page 94 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 LED Name MODE...
Page 95 REDUNDANT SYSTEM FUNCTIONS (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.) 2) 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...
Page 96 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...
Page 97 REDUNDANT SYSTEM FUNCTIONS (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 . 1) Write the redundant parameter in which "Start with Debug mode" is set into the CPU module, and power on the system again or set the RESET/L.CLR switch of the CPU module to reset switch neutral position.
Page 98 REDUNDANT SYSTEM FUNCTIONS (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. • System switching (including manual system switching) •...
Page 99: System Consistency Check
REDUNDANT SYSTEM FUNCTIONS 5.1.4 System Consistency Check In order to continue the redundant system control after system switching, the system configurations, parameters and programs of the control system and standby system must be consistent. In the backup mode, the standby system CPU module checks if the system configurations, parameters and programs of both systems are consistent.
Page 100 REDUNDANT SYSTEM FUNCTIONS Table5.10 Consistency Check Execution Conditions between System A and System B Conditions *1 Description Standby Control Parameter Execution Operation System System Operating Basic System Memory Card File Valid Drive Timing Mode Operating Operating Status Configuration Settings Settings Status Status Standby System...
Page 101 REDUNDANT SYSTEM FUNCTIONS (1) File Consistency Check (a) Check points The file consistency check means checking the following files at system switching as shown in Table5.11. 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 Parameters the intelligent function module parameters set with GX Configurator.
Page 102 REDUNDANT SYSTEM FUNCTIONS (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 System switching activated Refer Section 5.3 for system switching causes Tracking cable...
Page 103 REDUNDANT SYSTEM FUNCTIONS (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.
Page 104 • CPU module model • Model and type of modules mounted on each slot in the main base unit • Network module mode settings An error occurs because the CPU module type name is different Q25PRHCPU Q12PRHCPU MODE MODE Control Standby...
Page 105 REDUNDANT SYSTEM FUNCTIONS (b) Inconsistency Errors Table5.14 shows inconsistency errors that occur when the basic system configurations are inconsistent. Table5.14 Basic System Configuration Inconsistency Errors Execution Conditions Error Description • When both systems are powered ON simultaneously The following stop error will occur in the control •...
Page 106 REDUNDANT SYSTEM FUNCTIONS (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.
Page 107 REDUNDANT SYSTEM FUNCTIONS POINT 1. The memory card setting status consistency check does not include the memory card capacity check. When using memory cards of different capacities, check the capacity required for the actual control. If the special relay "Card removal/setting enable flag (SM609) is turned on and the memory card is changed during redundant system operation, an error does not occur since a memory card setting status consistency check is not performed.
Page 108 REDUNDANT SYSTEM FUNCTIONS (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 Standby system system...
Page 109: Self Diagnostics Function
REDUNDANT SYSTEM FUNCTIONS 5.1.5 Self Diagnostics Function (1) Self Diagnostics Function The self diagnostics function means that the redundant CPU checks for its own error, in order to prevent malfunction as well as to perform preventive maintenance. If an error occurs when the redundant system is powered on or while the redundant CPU is running, the redundant CPU detects the error and displays it and performs system switching, etc.
Page 110 REDUNDANT SYSTEM FUNCTIONS (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...
Page 111 REDUNDANT SYSTEM FUNCTIONS (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 develops a stop error.
Page 112: Start Mode
REDUNDANT SYSTEM FUNCTIONS 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.
Page 113 REDUNDANT SYSTEM FUNCTIONS POINT After system switching, the new control system will start up in the Hot-start mode regardless of the start mode settings. (2) Hot-start mode This mode is for performing the operation from when holding the device. (Some devices such as the step relay and the index register will be cleared.) As holding the devices even when the redundant system goes down due to power OFF or CPU module reset, the system can continue the operation when it is powered on or the CPU modules are unreset (RESET/L.CLR switch is set to the neutral...
Page 114 REDUNDANT SYSTEM FUNCTIONS (3) Differences Between Initial Start Mode and Hot-start Mode Table5.20 shows the differences between Initial start mode and Hot-start Mode. Table5.20 Differences Between Initial Start Mode and Hot-start Mode Initial Start Mode Hot Start Mode Not held in power OFF Cleared All Other Than Index Register Held...
Page 115: Function List
REDUNDANT SYSTEM FUNCTIONS 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. QCPU User's Manual (Function Explanation, Program Fundamentals) Table5.21 Function List Item Description Reference System Switching Function This function switches the control system and the standby system.
Page 116: The System Switching Function
REDUNDANT SYSTEM FUNCTIONS 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.
Page 117 REDUNDANT SYSTEM FUNCTIONS If system switching is performed in the backup mode, the following error codes will be stored into the error history of the new control system and new standby system CPU modules. In this case, the ERR. LED will remain off. (The ERR. LED does not turn on or flash.) •...
Page 118 REDUNDANT SYSTEM FUNCTIONS (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.
Page 119 REDUNDANT SYSTEM FUNCTIONS (b) System switching requested by the network module • When the control system CC-Link IE Controller Network module, MELSECNET/H module, or the Ethernet module detects a communication error or wire break , the module requests system switching to the CPU module.
Page 120 REDUNDANT SYSTEM FUNCTIONS POINT 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.
Page 121 REDUNDANT SYSTEM FUNCTIONS (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 control system CPU module.
Page 122 REDUNDANT SYSTEM FUNCTIONS POINT 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.
Page 123 REDUNDANT SYSTEM FUNCTIONS 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.
Page 124 REDUNDANT SYSTEM FUNCTIONS 2) Reasons for system switching can be set as system switching instruction parameter. M1000 SP.CONTSW K1 M10 Argument (Reason for system switching, etc.) Diagram 5.30 Example of System Switching Instruction programming The system switching instruction parameter value can be confirmed in the system switching instruction error details window, which can be displayed from the PLC Diagnostics screen.
Page 125 REDUNDANT SYSTEM FUNCTIONS (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. Diagram 5.32 Error Dialog Box Displayed on GX Developer (4) Operations When System Switching is Executed in the Standby System CPU Module...
Page 126: System Switching Execution Timing
REDUNDANT SYSTEM FUNCTIONS 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 System switching is executed when the reason for system Power off Automatic System...
Page 127: System Switching Execution Possibility
REDUNDANT SYSTEM FUNCTIONS 5.3.3 System Switching Execution Possibility (1) In Backup Mode System switching execution possibility in Backup Mode is shown in Table5.26 Table5.26 System Switching Execution Capability Control System Switching Condition Automatic System Switching Manual System Switching System System Standby System Operating Stop Error Switching...
Page 128 REDUNDANT SYSTEM FUNCTIONS Table5.27 Operating Status and Details Operating Status Description The CPU module is in the RUN, STOP or PAUSE status, where no error such as a continuation error or stop Normal 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.
Page 129 REDUNDANT SYSTEM FUNCTIONS Table5.28 Operations When System Switching Cannot Be Executed Due to Standby System Power Off, Resetting or Hardware Failure System Status After Operation After B System Power System Status Before System System Switching Control System OFF or unresetting the CPU System Switching Switching Condition...
Page 130 REDUNDANT SYSTEM FUNCTIONS Table5.30 Operations When System Switching Cannot Be Executed Due to Tracking Cable Disconnection System Status After System Control System Before System Switching System Switching Operation After Tracking Cable Switching Condition Switching Condition Disconnection Method System A System B System A System B Stop Error Other Than...
Page 131 REDUNDANT SYSTEM FUNCTIONS Table5.32 When System Switching Cannot Be Executed Due to Watchdog Timer Error of Standby System System Status After Status Before System System Operation After System B Power Control System System Switching Switching Switching Switching Condition Condition Method System A System B System A...
Page 132 REDUNDANT SYSTEM FUNCTIONS (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 Switching System Switching...
Page 133 REDUNDANT SYSTEM FUNCTIONS Table5.34 Operating Status and Details Operating Status Description The CPU module is in the RUN, STOP or PAUSE status, where no error such as a continuation error or stop Normal 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.
Page 134: Both Systems Operations After System Switching
REDUNDANT SYSTEM FUNCTIONS 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 New Control System CPU Module New Standby System CPU Module...
Page 135 REDUNDANT SYSTEM FUNCTIONS (2) Network Module Operations Table5.37 Control System and Standby System Network Operations After System Switching Item New Control System Network Module New Standby System Network Module Continues cyclic transmission. CC-Link IE Controller Network Starts cyclic transmission. However does not perform output. MELSECNET/H PLC to PLC Continues cyclic transmission.
Page 136: Special Relays/Registers For System Switching
REDUNDANT SYSTEM FUNCTIONS 5.3.5 Special Relays/Registers For System Switching (1) Special Relays For System Switching Special relays for system switching are shown in Table5.38 Table5.38 Special Relays For System Switching Setting at Time of System Switching Device Name Description New Control System New Standby CPU Module System CPU Module...
Page 137 REDUNDANT SYSTEM FUNCTIONS Table5.39 Special Registers For System Switching (Continued) Setting at Time of System Switching Device Name Description New Control System New Standby CPU Module System CPU Module Stores system switching condition that occurred on that system. Stores system switching condition even when system cannot switch due to system switching disenabling condition.
Page 138 REDUNDANT SYSTEM FUNCTIONS Table5.39 Special Registers For System Switching (Continued) Setting at Time of System Switching Device Name Description New Control System New Standby CPU Module System CPU Module • If an error occurs in the redundancy system error check, the following corresponding bits turn ON.
Page 139: System Switching Precautions
REDUNDANT SYSTEM FUNCTIONS 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).
Page 140 REDUNDANT SYSTEM FUNCTIONS (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.
Page 141: Operation Mode Change Function
REDUNDANT SYSTEM FUNCTIONS 5.4 Operation Mode Change Function 2 types of redundant system operation mode change are available. • Change from the backup mode to separate mode • 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 redundant operation of GX Developer.
Page 142 REDUNDANT SYSTEM FUNCTIONS (b) Changing From Separate Mode to Backup Mode 1) Connect GX Developer to the control system CPU module. 2) Select "Online" - "Redundant operation" from the menu bar of GX Developer to open the "Redundant operation" screen. 3) Open the GX Developer online Redundancy Procedure window.
Page 143 REDUNDANT SYSTEM FUNCTIONS 2) To change the operation mode back to backup mode, use the same GX 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.
Page 144 REDUNDANT SYSTEM FUNCTIONS • 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.
Page 145 REDUNDANT SYSTEM FUNCTIONS • 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. Diagram 5.42 Error Dialog Box Displayed on GX Developer •...
Page 146 REDUNDANT SYSTEM FUNCTIONS (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.
Page 147 REDUNDANT SYSTEM FUNCTIONS From Separate Mode to Backup Mode Control system Standby system Continues execution. Stops. Stops (continues). Stops (continues). Takes over the current setting. Takes over the current setting. Takes over the current setting. Changes to the DI status (interrupt disable). Takes over the current setting.
Page 148 REDUNDANT SYSTEM FUNCTIONS Table5.41 Operations When Changing Operation Mode (Continue) From Backup Mode to Separate Mode Function Control system Standby system Device memory Continues execution. SM/SD (system Stops tracking. dependent) Data tracking SFC information Stops tracking. Section 5.5.3) PID control instruction Stops tracking.
Page 149 REDUNDANT SYSTEM FUNCTIONS From Separate Mode to Backup Mode Control system Standby system Continues execution. Starts tracking. Starts tracking. Starts tracking. Starts tracking. Makes consistency check between System A & B for the following items. When an error is detected, a self-diagnostic error occurs in the standby system. •...
Page 150 REDUNDANT SYSTEM FUNCTIONS (a) Operations When Changing from Backup Mode to Separate Mode Back up mode Separate mode Calculating Stopping Calculation Calculating Start calculation Control Standby Control Standby system system system system Switch to separate mode Input data Input data Input data Input data Multiplexed...
Page 151 REDUNDANT SYSTEM FUNCTIONS Memo 5.4 Operation Mode Change Function - 68...
Page 152 REDUNDANT SYSTEM FUNCTIONS (3) Processing After Operation Mode Change Table5.42 indicates the redundant system operations after operation mode change. Table5.42 Operations After Operation Mode Change In Backup Mode Control System Standby System During Normal During Normal Item RUN and During During Stop RUN and During During Stop...
Page 153 REDUNDANT SYSTEM FUNCTIONS In Separate Mode Control System Standby System During Normal During Normal During Stop During Stop RUN and During During Stop RUN and During During Stop Error Error Resume Error Resume Error Executes the Executes the Does not execute the program Does not execute the program program program *3...
Page 154 REDUNDANT SYSTEM FUNCTIONS Table5.42 Operations After Operation Mode Change (Continue) In Backup Mode Control System Standby System During Normal During Normal Item RUN and During During Stop RUN and During During Stop During Stop During Stop Continuation Error Continuation Error Error Error Executes a refresh from the network...
Page 155 REDUNDANT SYSTEM FUNCTIONS 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...
Page 156: Tracking Function
REDUNDANT SYSTEM FUNCTIONS 5.5 Tracking Function 5.5.1 Tracking Function Overview (1) Tracking Function The tracking function maintains the data of the control system and standby systems consistent so that the redundant system can continue to operate with the standby system in case the control system goes down. As the tracking data settings have been made by the default in the redundant CPU, tracking can be done without changing the tracking settings.
Page 157 REDUNDANT SYSTEM FUNCTIONS (2) Tracking Data There are 2 types of tracking data: tracking data based on the range set by the user and tracking data regardless of the settings, i.e., automatic tracking data. (a) Tracking Data Range Setting by User The tracking data range and tracking timing can be set by the user.
Page 158 REDUNDANT SYSTEM FUNCTIONS (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: •...
Page 159: Tracking Execution Procedure
REDUNDANT SYSTEM FUNCTIONS 5.5.2 Tracking Execution Procedure The procedure for executing tracking in Diagram 5.48. Start Perfom tracking transfer according to defaults? Use GX Developer to change tracking setting redundancy parameters. Section 5.5.3 Use GX Developer to add tracking forwarding triggers to the controlling program .
Page 160: Tracking Data
REDUNDANT SYSTEM FUNCTIONS 5.5.3 Tracking Data Tracking data are shown in Table5.43 Table5.43 Tracking Data Settings Setting Operating Mode Auto Change by Type Description Backup Separate Tracking User Mode Mode Data of input (X), output (Y), internal relay (M) Internal Device and others used in programs Data turned ON or OFF by user or system Device...
Page 161 REDUNDANT SYSTEM FUNCTIONS Table5.44 Internal Devices That Can Be Tracked Device Default Tracking Range Tracking Range Set by User Input X0 to X1FFF X0 to X1FFF Output Y0 to Y1FFF Y0 to Y1FFF M0 to M8191 M0 to M8191 Internal relay L0 to L8191 L0 to L8191 Latch Relay...
Page 162 REDUNDANT SYSTEM FUNCTIONS 2) Changing the Internal Device Settings Internal device settings are changed in the following cases: Table5.45 Internal Device Settings Change Objective Tracking Setting • Change the settings so that only the devices actually used will be tracked. To shorten tracking time •...
Page 163 REDUNDANT SYSTEM FUNCTIONS (2) Automatic Tracking Data Automatic tracking data is the data that the redundant CPU tracks regardless of the redundant parameter tracking settings. The data settings cannot be changed by changing the redundant parameter tracking settings . This applies to the SFC data, PID control instruction data. some special relays and special registers.
Page 164 REDUNDANT SYSTEM FUNCTIONS (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 Number Name SD90 to SD99 Step transition watchdog timer setting value (Enabled only when SFC program exists) SD207 to SD209 LED display priority ranking SD210 to SD213...
Page 165: Tracking Data Settings
REDUNDANT SYSTEM FUNCTIONS 5.5.4 Tracking Data Settings Make the tracking data settings at Tracking settings in Redundant parameter in GX Developer. 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"...
Page 166 REDUNDANT SYSTEM FUNCTIONS * 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).
Page 167: Tracking Block And Tracking Trigger
REDUNDANT SYSTEM FUNCTIONS 5.5.5 Tracking Block And Tracking Trigger (1) Tracking Blocks (a) Tracking Block Overview 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.
Page 168 REDUNDANT SYSTEM FUNCTIONS (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. X0 to X1FFF Y0 to Y1FFF M0 to M8191 Table 5.42 "Default Transfer Range"...
Page 169 REDUNDANT SYSTEM FUNCTIONS (2) Tracking Trigger (a) Tracking Trigger Overview 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. ( Table5.49.) When executing tracking, turn on the tracking trigger that corresponds to each tracking No.
Page 170 REDUNDANT SYSTEM FUNCTIONS Table5.49 Tracking Triggers (Continued) Set By Number Name Description Default User or System SM1541 Tracking Block No. 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.
Page 171: Tracking Execution
REDUNDANT SYSTEM FUNCTIONS 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.
Page 172 REDUNDANT SYSTEM FUNCTIONS (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 Device Data PID Control Special Relay Control System Standby System Signal Flow SFC Data...
Page 173: Tracking Mode
REDUNDANT SYSTEM FUNCTIONS 5.5.7 Tracking Mode Tracking mode determines processing when a new tracking request occurs before the previous tracking processing is completed. (If the previous tracking has been completed while the control system CPU module is executing the END processing, the next tracking will be initiated.) There are 2 types of tracking modes: •...
Page 174 REDUNDANT SYSTEM FUNCTIONS (2) Synchronized Tracking Mode This method performs tracking to the standby system for each scan while the control system CPU module is executing the END processings. If the previous tracking is not complete during END processing, the system will wait and perform the next tracking after it has been completed.
Page 175 REDUNDANT SYSTEM FUNCTIONS (b) Program Priority Mode In program priority mode, the control system CPU module executes the scan execution type program as soon as tracking starts. If tracking time is longer than program execution time, the next tracking cannot start until the current tracking is completed.
Page 176 REDUNDANT SYSTEM FUNCTIONS (3) Asynchronous Tracking Mode In this mode, the control system CPU prioritizes program operation over tracking processing. If the previous tracking is not complete while executing the END processings, the control system CPU module suspends the next tracking and starts the program operation.
Page 177 REDUNDANT SYSTEM FUNCTIONS (b) Tracking in Separate Mode Scan time Prepare Tracking data 3) Prepare Tracking Prepare Tracking data 1) data 2) Control system END/0 END/0 CPU module program 1) program 2) program 3) program 4) program 5) program 6) New Standby system CPU module Send...
Page 178: Device Data Used By The New Control System
REDUNDANT SYSTEM FUNCTIONS 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.
Page 179: Online Program Change For Redundancy
REDUNDANT SYSTEM FUNCTIONS 5.6 Online Program Change for Redundancy In the backup mode, GX Developer writes the same program to the control system and standby system CPU modules to keep them consistent. Write to the control system and standby system is executed in the following conditions: •...
Page 180 REDUNDANT SYSTEM FUNCTIONS (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 •...
Page 181 REDUNDANT SYSTEM FUNCTIONS (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: Diagram 5.62 Error Dialog Box Displayed on GX Developer Access the files again after the writing operation has been completed.
Page 182 REDUNDANT SYSTEM FUNCTIONS (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. •...
Page 183: Program Change While Cpu Is Running
REDUNDANT SYSTEM FUNCTIONS 5.6.2 Program Change While CPU is Running Data are written to both systems while CPU is running, in the following cases: • Online program change • Writing files in RUN • T/C set value change Refer to the following manual for details on the above operations. 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...
Page 184 REDUNDANT SYSTEM FUNCTIONS (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. •...
Page 185 REDUNDANT SYSTEM FUNCTIONS (a) When SM1710 is OFF (Default) When SM1710 is off, tracking will be suspended until online program change is complete. If a system switching occurs during online program change, the new control system CPU module may output old data. For example, if output (Y) is turned on in the control system during online program change, the output (Y) on information will not be tracked to the standby system CPU module since tracking has not been performed.
Page 186 REDUNDANT SYSTEM FUNCTIONS (b) When SM1710 is ON 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 Y100...
Page 187 REDUNDANT SYSTEM FUNCTIONS However, even if the program of the new control system CPU module has not been changed due to the system switching timing, the data calculated in the previous control system after system switching may be tracked. System A CPU module System B CPU module Control system Standby system...
Page 188 REDUNDANT SYSTEM FUNCTIONS (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 System Switching Execution Type System Switching Condition During RUN Write Stop error System switching request by network module...
Page 189 REDUNDANT SYSTEM FUNCTIONS (6) Special Relays And Special Registers For Online Program Change (a) Special Relays For Online Program change Special relays for online program change are shownin Table5.55 Table5.55 Special Relays For Online Program change Number Name Explanation Turning this relay from OFF to ON enables manual system switching during online program change redundant tracking.
Page 190 REDUNDANT SYSTEM FUNCTIONS (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.
Page 191 REDUNDANT SYSTEM FUNCTIONS (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: Diagram 5.71 Error Dialog Box Displayed on GX Developer (e) Access to programs being changed online...
Page 192 REDUNDANT SYSTEM FUNCTIONS 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: Diagram 5.75 Error Dialog Box Displayed on GX Developer 4) Online program change to CPU module during system switching or operation mode change...
Page 193 REDUNDANT SYSTEM FUNCTIONS (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 programs of the control system and standby system CPU modules are temporarily different.
Page 194: Memory Copy From Control System To Standby System
REDUNDANT SYSTEM FUNCTIONS 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.
Page 195 REDUNDANT SYSTEM FUNCTIONS (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 Set by User Type Number Description Remarks or System Turn on this relay to start memory copy after storing...
Page 196 REDUNDANT SYSTEM FUNCTIONS (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"...
Page 197 Developer and the relevant operations. (a) Procedure 1) Connect the control system and standby system CPU modules with a tracking cable and power on the standby system. Control system CPU module Standby system CPU module ON (red) Q12PRHCPU Q12PRHCPU MODE BACKUP MODE BACKUP CONTROL CONTROL ERR.
Page 198 This transfers the control system data to the standby system. 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 Flashing (red) Q12PRHCPU Q12PRHCPU MODE BACKUP MODE BACKUP...
Page 199 REDUNDANT SYSTEM FUNCTIONS 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 ON (red) Q12PRHCPU Q12PRHCPU MODE BACKUP MODE BACKUP CONTROL CONTROL ERR.
Page 200 (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 ON (red) Q12PRHCPU Q12PRHCPU MODE BACKUP MODE BACKUP CONTROL CONTROL ERR.
Page 201 (SM1595) is turned ON, the contents of control system memory will be copied to the standby system. Then, the "BACKUP" LED of the standby system CPU module will turn ON (red). Control system CPU module Standby system CPU module Flashing (red) Q12PRHCPU Q12PRHCPU MODE BACKUP MODE BACKUP CONTROL CONTROL ERR.
Page 202 REDUNDANT SYSTEM FUNCTIONS (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 system Standby system Tracking cable Tracking cable 1) Be sure that SM1596, SM1597 are OFF and Turn ON SM1595.
Page 203 REDUNDANT SYSTEM FUNCTIONS POINT 1. 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"...
Page 204 REDUNDANT SYSTEM FUNCTIONS (4) Error Occurrence During Memory Copy 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"...
Page 205 REDUNDANT SYSTEM FUNCTIONS (b) Restrictions on Memory Copy Memory copy cannot be done using either GX Developer or the special relays and special registers under the conditions shown in Table5.60. Table5.60 Restrictions on Memory Copy Memory Copy Operation Memory Copy Using Special Execution Conditions Memory Copy Using GX Developer Relays and Special Registers...
Page 206: Online Module Change (Hot Swapping)
REDUNDANT SYSTEM FUNCTIONS 5.8 Online Module Change (Hot Swapping) In the redundant system, following modules can be replaced online. • Module mounted to the extension base unit (I/O module, analog module etc.) • Module mounted to the remote I/O station in the MELSECNET/H Remote I/O network (I/O module, analog module etc.) •...
Page 207 REDUNDANT SYSTEM FUNCTIONS (3) 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.
Page 208: Network Module Redundant Group Settings
REDUNDANT SYSTEM FUNCTIONS 5.9 Network Module Redundant Group Settings (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.
Page 209 REDUNDANT SYSTEM FUNCTIONS (2) Redundant Group Settings Redundant group settings are made in the network parameter group settings using GX Developer. Set "Group" or leave it block in the network module set to the lower I/O No. When module No. 3 is set in "Group", module No.
Page 210: Redundant Cpu Functions Restricted In Redundant System
REDUNDANT SYSTEM FUNCTIONS 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 • Remote operation Refer to the following manual for details of each function. 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...
Page 211 REDUNDANT SYSTEM FUNCTIONS (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"...
Page 212 REDUNDANT SYSTEM FUNCTIONS (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...
Page 213 REDUNDANT SYSTEM FUNCTIONS (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.
Page 214: Remote Operation For Redundant System
REDUNDANT SYSTEM FUNCTIONS 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.) •...
Page 215 REDUNDANT SYSTEM FUNCTIONS (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.
Page 216 REDUNDANT SYSTEM FUNCTIONS (b) Remote operation for both systems When "Both systems (A & B)" is selected at the execution destination area on the Remote operation screen of GX Developer, remote operation is performed for the control system and standby system. Remote operation for "Both systems"...
Page 217 REDUNDANT SYSTEM FUNCTIONS (3) Remote reset operation (a) In the backup mode In the backup mode, performing remote reset operation for the control system resets both systems. (Both systems are reset also when "Currently specified station" is selected at the execution destination area on the Remote operation screen of GX Developer.) STOP STOP...
Page 218 REDUNDANT SYSTEM FUNCTIONS 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. 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.
Page 219 REDUNDANT SYSTEM FUNCTIONS (c) Precautions when executing remote reset operation The following describes the precautions to be taken when performing remote reset for both systems in the backup mode. 1) Remote reset when control system CPU module is in the STOP status and standby system CPU module is in the RUN status System switching will occur when remote reset operation is performed for the control system CPU module when the control system CPU module is in the...
Page 220 REDUNDANT SYSTEM FUNCTIONS 2) When watchdog timer error has occurred in the standby system CPU module When a watchdog timer error has occurred in the standby system CPU module, only the control system CPU module is reset and the standby system CPU module is not reset.
Page 221 REDUNDANT SYSTEM FUNCTIONS 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.
Page 222: Access To Module Mounted On Extension Base Unit
REDUNDANT SYSTEM FUNCTIONS 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 Access from control system Access from standby system Execution...
Page 223 REDUNDANT SYSTEM FUNCTIONS Table5.65 Access to Module Mounted on Extension Base Unit (Continued) Execution Access from control system Access from standby system Item Name timing Backup mode Separate mode Backup mode Separate mode Intelligent function module Dedicated Dedicated At instruction Inexecutable Inexecutable Inexecutable...
Page 224: Chapter6 Redundant System Networks
REDUNDANT SYSTEM NETWORKS 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.
Page 225 REDUNDANT SYSTEM NETWORKS Table6.1 GX Developer System Specification and Communication Paths System Communication Path Specification System A - Control System System B - Standby System System not specified (default) Not specified • Select this option to communicate with only the (Default) CPU module connected to GX Developer.
Page 226: Confirming The Connection Target On Gx Developer
REDUNDANT SYSTEM NETWORKS 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 monitor status (control system/standby system and System A/System B).
Page 227: Cautions On Access From Gx Developer And Px Developer
REDUNDANT SYSTEM NETWORKS 6.1.3 Cautions on Access from GX Developer and PX Developer This section describes cautions on access from GX Developer and PX Developer. (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 When the system for the CPU module to which GX Developer/PX Developer is connected is different from the specified system, communication is done with the...
Page 228 REDUNDANT SYSTEM NETWORKS (2) Corrective Action when a Line Down Occurs during Access via a Network (a) In the case of other than monitoring A communication error occurs when accessing to a module mounted on the extension base unit via the network using the function other than [Monitor] of GX Developer or PX Developer.
Page 229 REDUNDANT SYSTEM NETWORKS [Example] If a line down occurs in system A during access when PX Developer (monitoring tools) is connected to that system, and the connection target is specified as system A, communication is continued with system A via system B. GX Developer Ethernet The line is down...
Page 230: Redundant System Network Overview
REDUNDANT SYSTEM NETWORKS 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.) • CC-Link IE Controller Network • MELSECNET/H PLC to PLC network •...
Page 231 REDUNDANT SYSTEM NETWORKS Personal computer Ethernet CC-Link IE Controller Network Multiplexed Remote Master Station Multiplexed Remote Sub-master Station QCPU QCPU QCPU (Normal (Normal (Normal System A - System B - Master station Standby Master station station) station) station) Control System Standby System DP-Slave DP-Slave PROFIBUS-...
Page 232: Cc-Link Ie Controller Network Or Melsecnet/H Plc To Plc Network
REDUNDANT SYSTEM NETWORKS 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.
Page 233 REDUNDANT SYSTEM NETWORKS (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 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...
Page 234 REDUNDANT SYSTEM NETWORKS (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.
Page 235 REDUNDANT SYSTEM NETWORKS [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 No.
Page 236 REDUNDANT SYSTEM NETWORKS (b) Operation of New Standby System Network Module The new standby system network module that has developed a communication error is cut off from the network. When the network communication error is cleared, the new standby system network module is returned to the network as the normal station.
Page 237 REDUNDANT SYSTEM NETWORKS (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 system. For the control stations of network systems connected to a redundant system, make sure to make the pairing settings for the station Nos.
Page 238 REDUNDANT SYSTEM NETWORKS Pairing settings can be made for the following CPU modules that can work as the control station. • Redundant CPU • High performance model QCPU • Process CPU • Basic model QCPU • Universal model QCPU *1 *2 •...
Page 239 REDUNDANT SYSTEM NETWORKS (7) Precautions for Using Redundant System in CC-Link IE Controller Network or MELSECNET/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.
Page 240: Melsecnet/H Remote I/O Network
REDUNDANT SYSTEM NETWORKS 6.2.2 MELSECNET/H Remote I/O network A redundant system uses a multiplexed remote I/O system of MELSECNET/H remote I/O network to continue the control of remote I/O stations even when system switching occurs. The multiplexed remote I/O network system consists of "multiplexed remote master station"...
Page 241 REDUNDANT SYSTEM NETWORKS (2) Redundant System Operation at System Switching When system switching occurs, the new control system network module operates as the master station, and takes over the control of remote I/O stations. Diagram 6.14 shows a redundant system operation when a stop error occurs in the control system CPU module.
Page 242 REDUNDANT SYSTEM NETWORKS (3) Redundant System Operation 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.
Page 243 REDUNDANT SYSTEM NETWORKS (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.
Page 244 REDUNDANT SYSTEM NETWORKS (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.
Page 245 REDUNDANT SYSTEM NETWORKS (6) Startup Order of System A and System B No restrictions apply to the startup order of system A and system B when connected to the MELSECNET/H remote I/O network. After starting up system A and system B, the control system and standby system are determined, and then the data link is started.
Page 246 REDUNDANT SYSTEM NETWORKS (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 station) and standby system (sub-master station).
Page 247 REDUNDANT SYSTEM NETWORKS (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 settings in PLC parameter. Diagram 6.19 In the case of Redundant CPU Diagram 6.20 In the case of Remote I/O Station Different error-time operation modes can be set to the Redundant CPU (remote...
Page 248 REDUNDANT SYSTEM NETWORKS (b) Operation when error occurs in remote I/O station Table6.4 Operation When Error Occurs in remote I/O station Settings of operation mode for Data link operation of Redundant CPU Output operation from remote error occurrence MELSECNET/H remote I/O Redundant Remote I/O control status...
Page 249: Ethernet
Mitsubishi Electric, which consists of the Windows API (Application Programming Interface). By using EZ Socket, each partner company can easily develop FA-related application ® software using FA devices made by Mitsubishi Electric, which operate on Windows personal computers. POINT Ethernet module can be mounted to the main base unit or extension base unit.
Page 250 REDUNDANT SYSTEM NETWORKS 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.
Page 251 REDUNDANT SYSTEM NETWORKS (1) Overview of Communication with External Devices (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. (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...
Page 252 REDUNDANT SYSTEM NETWORKS (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.
Page 253: Cc-Link
REDUNDANT SYSTEM NETWORKS 6.2.4 CC-Link A redundant system can continue the CC-Link control by CC-Link standby master function, even when system switching occurs. 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.
Page 254 REDUNDANT SYSTEM NETWORKS (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 data from the remote stations and sends/receives data to/from the master station, in order to continue the CC-Link control even when system switching occurs.
Page 255 REDUNDANT SYSTEM NETWORKS (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.
Page 256 REDUNDANT SYSTEM NETWORKS (b) When System Switching Occurs due to Communication 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.
Page 257 REDUNDANT SYSTEM NETWORKS (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. However, the new standby system master station does not switch to the standby master station, as it can communicate with remote stations.
Page 258 REDUNDANT SYSTEM NETWORKS (3) Programs for Switching the Standby Master Station that Controls 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.
Page 259 REDUNDANT SYSTEM NETWORKS (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. (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.
Page 260: Serial Communication Modules
REDUNDANT SYSTEM NETWORKS 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.
Page 261 REDUNDANT SYSTEM NETWORKS (1) Communication between External Devices and Control System CPU Module (a) Communication by MC Protocol 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. (Appendix 7 (1)) In addition, when system switching occurs, the communication timeout will occur since both old system and new system cannot respond.
Page 262 REDUNDANT SYSTEM NETWORKS 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.
Page 263 REDUNDANT SYSTEM NETWORKS (2) Communication between External Devices and the Standby System CPU Module (a) Communication by MC Protocol 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"...
Page 264 REDUNDANT SYSTEM NETWORKS (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"...
Page 265: Profibus-Dp
REDUNDANT SYSTEM NETWORKS 6.2.6 PROFIBUS-DP (1) Communication overview of the PROFIBUS-DP In redundant system, when the PROFIBUS-DP master module detects a fault or communication failure with DP-Slaves, the standby system master module is switched to new control system master module and inherits the PROFIBUS communications. (2) Operation at system switching The PROFIBUS-DP master modules switch each system on the following cases.
Page 266 REDUNDANT SYSTEM NETWORKS (3) Line redundant system The line redundant system allows the system configuration using 2 lines, and either of the lines is used for slave station control. When an error occurs at the controlling line, the control is inherited to another line. (4) Station number setting Set the station number of the PROFIBUS-DP master module with GX Developer and GX Configurator-DP.
Page 267: Communication Between The Both Systems Cpu Module And Gots
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, refer to the following manual. GOT1000 Series Connection Manual (Mitsubishi Products) Table6.7 Connection Method of GOT and its Connectability in Redundant System Connection method...
Page 268 REDUNDANT SYSTEM NETWORKS Personal GOT1000 Series computer GOT-A900 Series (Ethernet connection) Ethernet CC-Link IE Controller Network GOT1000 Series GOT1000 Series GOT1000 Series QCPU GOT-A900 Series GOT-A900 Series (CC-Link IE Controller (Normal (CPU directly connected) (CPU directly connected) Network connection) station) Tracking cable GOT1000 Series Extension base unit...
Page 269: When Connecting Gots To Melsecnet/H Remote I/O Station
REDUNDANT SYSTEM NETWORKS 6.3.1 When connecting GOTs to MELSECNET/H remote I/O station For MELSECNET/H network connection, connect GOTs to a remote I/O module or serial communication module mounted on a MELSECNET/H remote I/O network remote I/O station. 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.
Page 270 Therefore, the GOT communicates with the new control system CPU module. For details, refer to the following manual. GOT1000 Series Connection Manual (Mitsubishi Products) - 47 6.3 Communication between the Both Systems CPU Module and GOTs...
Page 271: When Connecting Gots To Cc-Link
CPU module. (When connection is made via the extension base unit, the GOT always monitors the control system.) For details, refer to the following manual. GOT1000 Series Connection Manual (Mitsubishi Products) 6.3 Communication between the Both Systems CPU Module and GOTs - 48...
Page 272: Communication When The Got Is Connected To Cc-Link Ie Controller Network, Melsecnet/H, Or Melsecnet/10 Plc To Plc Network
For the function to enable this automatic changing of the monitoring target at the GOT, refer to the following manual. GOT1000 Series Connection Manual (Mitsubishi Products) (b) GOT-A900 series The GOT specifies the target communication station connected to the MELSECNET/10 PLC to PLC network by the network No.
Page 273: When Connecting Gots To A Ethernet
REDUNDANT SYSTEM NETWORKS 6.3.4 When Connecting GOTs to a Ethernet The GOT is connected to Ethernet module mounted on the main base unit or Ethernet module mounted on the extension base unit. (1) GOT Connection Methods Connect GOTs to a Ethernet via "Ethernet connection". GOT1000 series GOT-A900 series (Ethernet connection)
Page 274 For the function to enable this automatic changing of the monitoring target at the GOT, refer to the following manual. GOT1000 Series Connection Manual (Mitsubishi Products) (b) GOT-A900 series The GOT specifies the target communication station connected to Ethernet by the network No.
Page 275: Precautions For Accessing Redundant Cpu From Other Networks
REDUNDANT SYSTEM NETWORKS 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.
Page 276 REDUNDANT SYSTEM NETWORKS [Example] 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.) GX Developer Control system specified...
Page 277: Precautions For Writing Device Data From Other Station
REDUNDANT SYSTEM NETWORKS 6.5 Precautions for Writing Device Data from Other Station (1) Operation When System Switching Occurs Until Tracking Is Completed When the devices of the control system CPU module where data have been written are set to within the tracking range, the device data written in the control system CPU module are also tracked to the standby system CPU module.
Page 278 REDUNDANT SYSTEM NETWORKS (b) Checking for system switching by system A and system B identification flags Whether system switching occurred or not can be confirmed by checking the system A and system B identification flags before and after write of device data. Start Specify the control system and read the following special relays:...
Page 279: Chapter7 Programming Cautions
PROGRAMMING CAUTIONS CHAPTER7 PROGRAMMING CAUTIONS This chapter provides the programming cautions (restrictions on instructions, and fixed- scan clocks and fixed scan execution type programs). 7.1 Instructions Restricted in Use for Redundant System Some instructions are restricted in use to a redundant system as indicated below. (1) Instructions Requiring a Certain Number of Scans (a) Instruction Operations Some instructions require a certain number of scans from start to completion of...
Page 280 PROGRAMMING CAUTIONS (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. However, note that the same instruction might be executed twice. [Example] In the following program example, when system switching occurs during execution of the REMFR instruction (M201 : ON) in an MELSECNET/H remote...
Page 281 PROGRAMMING CAUTIONS • 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. SM1518 M201 Turns ON M202 when system M202 switching occurs during execution of the REMFR instruction. SM1518 SB20 SB47 SB48 SB49 SW70.9 SW74.9 M203 M200...
Page 282 PROGRAMMING CAUTIONS (2) Rise Instruction 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 execution condition is satisfied before the systems are switched.
Page 283 PROGRAMMING CAUTIONS (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 during system switching processing. (a) When signal flow memory has not been tracked Jumping is executed from the first scan after system switching.
Page 284 PROGRAMMING CAUTIONS (5) Instructions that Change CPU Status When the instruction listed in Table7.3 is executed and the control system CPU module status changes, the information of the changed status will not be sent to the standby system CPU module. Therefore, if system switching occurs, it is necessary to use the user program to execute that instruction in the new control system CPU, as necessary.
Page 285 PROGRAMMING CAUTIONS (b) Relevant Instructions • PLS • P(Examples: MOVP,INCP, etc.) • SP. ,GP. ,ZP. ,JP. (Intelligent Function Module Dedicated Instructions) (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.
Page 286 PROGRAMMING CAUTIONS Remark Refer to the following manual for details of the COM instruction and ZCOM instruction. MELSEC-Q/L Programming Manual (Common Instruction) (8) Dedicated instructions for intelligent function module mounted to extension base unit The dedicated instructions for the intelligent function module mounted to the extension base unit cannot be used.
Page 287: Cautions On Fixed-Scan Clocks And Fixed Scan Execution Type Programs
PROGRAMMING CAUTIONS 7.2 Cautions on Fixed-Scan Clocks and Fixed Scan Execution Type Programs (1) Fixed-scan Clocks (SM409 to SM415) When system switching occurs, fixed-scan clock measurement is suspended until system switching is complete. When system switching is complete, the new control system CPU module starts all fixed-scan clocks from OFF.
Page 288 PROGRAMMING CAUTIONS (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+ ') as shown in Diagram 7.8.
Page 289 PROGRAMMING CAUTIONS (4) Interrupt by the Internal Timer (I28 to I31) 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.
Page 290 PROGRAMMING CAUTIONS (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...
Page 291 PROGRAMMING CAUTIONS (6) Interrupt during Tracking Processing If interrupt is enabled (EI 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. [Example] The operations for interrupted (I31) execution via an internal timer are shown in Diagram 7.10.
Page 292: Precautions For Using Annunciator (F) In Redundant System
PROGRAMMING CAUTIONS 7.3 Precautions for Using Annunciator (F) in Redundant System The annunciator defaults to no tracking. In the tracking setting of the Redundant parameter dialog box, the annunciator can be set to within the tracking range. Table7.6 provides an operation example of the control system and standby system CPU modules when the annunciator is set to within the tracking range and the annunciator (F10) is turned ON in the control system CPU module.
Page 293 PROGRAMMING CAUTIONS 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"...
Page 294 PROGRAMMING CAUTIONS (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. Tracking is executed SM1518 F10 is turned on at the second scan...
Page 295: Precautions At System Switching Occurrence
PROGRAMMING CAUTIONS 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.
Page 296 PROGRAMMING CAUTIONS • Input is returned corresponding to output Response (input) (X10) Output (Y10) [Program example] Error occurrence Scan execution Scan execution type program type program Prepare tracking transfer data Prepare tracking Wait transfer data Wait Control system CPU module Send Send Send...
Page 297 PROGRAMMING CAUTIONS 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.
Page 298 PROGRAMMING CAUTIONS (b) Output is returned corresponding to external input Response (input) (X10) Output (Y10) [Program example] (Before measures) (After measures) Delays SET Y10 by one scan from PLS M1. Delays RST Y10 by one 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].
Page 299 PROGRAMMING CAUTIONS 3) When output (output (Y), writing to buffer memory) is performed from the timer contact, the timer goes into the above-mentioned 2) status, which leads to chattering of the output. When the CPU module communicates with the module or external device using the output (Y) and buffer memory, the program may not operate normally due to chattering of the output after system switching.
Page 300 PROGRAMMING CAUTIONS 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.
Page 301: Precautions Of Programming When Connecting Extension Base Unit
PROGRAMMING CAUTIONS 7.5 Precautions of Programming when Connecting Extension Base Unit 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.
Page 302: Chapter8 Troubleshooting
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. Q12PRHCPU MODE BACKUP CONTROL ERR.
Page 303 TROUBLESHOOTING Table8.1 LED Names and Explanations (Continued) Name Explanation : An error has been detected with the CHK instruction, or annunciator F turns on. USER LED : Normal. Flashing : Latch clear is executed. : A battery error has occurred due to battery voltage drop in the CPU BAT.LED module or memory card.
Page 304: Troubleshooting Flow
TROUBLESHOOTING 8.1 Troubleshooting Flow This section provides the troubleshooting for each possible case. Error Details Section 8.1.4 To the flow for when the "RUN" LED does not light up The "MODE" LED does not light up The "BACKUP" LED is lit up solid red Section To the flow for when the...
Page 305: Flow For The Case Where The "Mode" Led Is Not On
CPU module installed, and slowly build up from this. For modules that are not functioning, please Mitsubishi contact the nearest represenative , reseller or branch office and explain the fault symptoms.
Page 306: When The Cpu Module "Backup" Led Is On (Red)
TROUBLESHOOTING 8.1.2 When the CPU Module "BACKUP" LED is ON (Red) The following flow (Diagram 8.4) is for the case where the "BACKUP" LED of the CPU module is on (red) while the redundant system is running. The "BACKUP" LED is lit up solid red Is the standby system's power Turn ON the standby system power...
Page 307 TROUBLESHOOTING Power off the standby system. Disconnect and then reconnect the Section 3.3 tracking cable. ( Power on the standby system. Reset the error of the control system Section 8.2 CPU module. (Refer to Is the "BACKUP" LED lit green? Replace the tracking cable.
Page 308 ( Is the "BACKUP" LED lit up solid green? Please contact the nearest Mitsubishi represenative , reseller or branch office and explain the fault Completed symptoms. 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.
Page 309: When The "System A/B" Led Is Flashing
TROUBLESHOOTING 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 "SYSTEM A/B" LED is flashing while the redundant system is running. The "SYSTEM A/B" LED is flashing Has the tracking cable been connected to the...
Page 310 Is the "SYSTEM A/B" 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 8.1 Troubleshooting Flow...
Page 311: When The System A/System B Cpu Module "Run" Led Is Not On
TROUBLESHOOTING 8.1.4 When the System A/System B CPU module "RUN" LED is not ON The following flow (Diagram 8.6) is for the case where the System A/System B CPU module "RUN" LED is not on. The "RUN" LED does not light up (Separate mode)*3 Is the running mode set to backup...
Page 312 System This is a hardware fault in the CPU Monitor / PLC diagnostics. *4 module, so please contact the nearest Mitsubishi represenative, reseller or branch office and explain the fault symptoms. Please contact the nearest Mitsubishi...
Page 313: When System Switching Has Occurred
TROUBLESHOOTING 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. 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.
Page 314 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. Diagram 8.7 Flow for the Case where System Switching Occurred * 1: When using the CPU module whose first 5 digits of serial No.
Page 315: When System Switching Has Failed
"systems did not switch." If the systems do not switch for the same reason even after performing the above checks, please contact the nearest Mitsubishi represenative, reseller or branch office and explain the fault symptoms. Diagram 8.8 Flow for the Case where System Switching Has Failed 8.1 Troubleshooting Flow...
Page 316 TROUBLESHOOTING (2) In the Case of System Switching due to Control System Error or System Switching Instruction Execution Systems did not switch NO (Debug mode) Is the "BACKUP" LED lit? Turn off debug mode redundancy Green / Red (Backup Mode) parameters and change to backup Amber (Separate Mode) mode.
Page 317 Mitsubishi represenative, reseller or branch office and explain the fault symptoms. * 1 : The CPU module ERR. LED is flashing when a stop error has occurred.
Page 318 TROUBLESHOOTING Has an operation error occurred from the control system's system switching instruction? 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...
Page 319 Is SD16=10? Check operation starting from a minimum system and work your way up.For modules that are not functioning, contact the nearest Mitsubishi represenative, reseller or For the control system branch office and explain the fault network module, are there symptoms.
Page 320: When "Trk. Init. Error (Error Code: 6140)" Occurred At Redundant System Startup
TROUBLESHOOTING 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.
Page 321: When "Control Sys. Down (Error Code: 6310 To 6312)" Occurred At Redundant System
TROUBLESHOOTING 8.1.8 When "CONTROL SYS. DOWN (error code: 6310 to 6312)" Occurred at Redundant System Startup (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. •...
Page 322: When "Etx.cable Err." Occurs
Hardware failure of the following modules is suspected. CPU module Main base unit or extension base unit Extension cable Consult your local Mitsubishi service Completed representative, explaining a detailed description of the problem. Diagram 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.
Page 323: When "Base Lay Error" Occurs
Hardware failure of the following modules is suspected. Extension base unit Extension cable Consult your local Mitsubishi representative, explaining a detailed description of the problem. 8.1 Troubleshooting Flow - 22 8.1.10 When "BASE LAY ERROR" Occurs...
Page 324 Extension base unit CPU module may have hardware failure. Extension cable Consult your local Mitsubishi representative, Consult your local Mitsubishi representative, explaining a detailed description of the problem. explaining a detailed description of the problem. Diagram 8.11 Flowchart for when "BASE LAY ERROR" Occurs - 23 8.1 Troubleshooting Flow...
Page 325: When "Unit Lay. Diff." Occurs
CPU module are mounted. For a module which does not operate, consult your local Mitsubishi representative, explaining a detailed description of the problem. Diagram 8.12 Flowchart for when "UNIT LAY. DIFF." Occurs 8.1 Troubleshooting Flow...
Page 326: When "Sp. Unit Down" Occurs
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. Diagram 8.13 Flowchart for when "SP. UNIT DOWN" Occurs - 25 8.1 Troubleshooting Flow...
Page 327: When "Sp. Unit Lay Error" Occurs
Rewrite the network parameters. Are the parameter contents normal? A hardware failure occurs to the CPU module. Consult your local Mitsubishi representative, explaining a detailed description of the problem. Diagram 8.14 Flowchart for when "SP. UNIT LAY ERROR" Occurs 8.1 Troubleshooting Flow - 26 8.1.13 When "SP.
Page 328: When "Link Para. Error" Occurs
TROUBLESHOOTING 8.1.14 When "LINK PARA. ERROR" Occurs 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 Recheck the pairing settings. made to the Redundant CPUs in the normal station? Is the number of...
Page 329 Rewrite the network parameters. Are all parameter contents normal? A hardware failure occurs to the CPU module. Consult your local Mitsubishi representative, explaining a detailed description of the problem. Diagram 8.15 Flowchart for when "LINK PARA. ERROR" Occurs 8.1 Troubleshooting Flow - 28 8.1.14 When "LINK PARA.
Page 330: When "Sp. Unit Ver. Err." Occurs
"D". function version "D" used? 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. Diagram 8.16 Flowchart for when "SP. UNIT VER. ERR." Occurs - 29 8.1 Troubleshooting Flow...
Page 331: 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
TROUBLESHOOTING 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 (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...
Page 332 TROUBLESHOOTING (2) How to cancel "CAN'T SWITCH" 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"...
Page 333: Error Clear
TROUBLESHOOTING 8.2 Error Clear In a redundant system, the errors that continue the CPU module operation can be cleared. The following methods for error clear are available in a redundant system. • Clearing the host CPU module error • Clearing the standby system CPU module error by the control system CPU module (This includes clearing the standby system CPU module error by GX Developer connected to the control system CPU module.)
Page 334 TROUBLESHOOTING 4) Error clear processing is performed by END processing. Therefore, an error cannot be cleared unless the END instruction is executed with SM50 ON. (2) Clearing the Standby System CPU Module Error by the Control System CPU Module A standby system CPU module error is cleared with the user program of the control system CPU module, using SM1649 and SD1649.
Page 335 TROUBLESHOOTING 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.
Page 336 TROUBLESHOOTING (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.
Page 337: Replacing Module In Redundant System
TROUBLESHOOTING 8.3 Replacing Module in Redundant System 8.3.1 CPU Module Replacement (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.
Page 338 TROUBLESHOOTING 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 Remove the standby 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.
Page 339: Power Supply Module Replacement Procedure
TROUBLESHOOTING 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. Power supply module Control Standby...
Page 340 TROUBLESHOOTING (2) Replacement Procedure The procedure for replacing the power supply modules is shown in Diagram 8.24. Start 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.
Page 341: Redundant Power Supply Replacement Procedure
TROUBLESHOOTING 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.
Page 342: I/O Module Replacement Procedure
TROUBLESHOOTING 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.
Page 343 TROUBLESHOOTING (3) Replacement Procedure during Power OFF The I/O module replacement procedure is shown in Diagram 8.28. Start 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.
Page 344: Network Module Replacement Procedure
TROUBLESHOOTING 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 Tracking cable...
Page 345 TROUBLESHOOTING Disconnecting the Cable Disconnect the network cable from the target network module. Refer to the manual of the network module, for disconnecting the network cable. Replacing the Standby System's Network Module 1) Disconnect the network module from the main base unit. 2) Attach the replacement network module (a network module of the same type as the control system network module).
Page 346: Main Base Unit Replacement Procedure
TROUBLESHOOTING 8.3.6 Main Base Unit Replacement Procedure (1) Main Base Unit Replacement The control system main base unit cannot be replaced while the redundant system is running. In this case, switching its system to the standby system, then replace that main base unit.
Page 347 TROUBLESHOOTING (2) Replacement Procedure The replacement procedure for the main base unit is indicated in Diagram 8.34. Start Confirming the Main Base Unit Targeted for Replacement Confirm that the main base unit to be replaced is for the standby system (CONTROL LED is off).When replacing the control system's power supply module, switch it to be the standby system using GX Developer's system switching.
Page 348 TROUBLESHOOTING 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).
Page 349: Procedure For Replacing Module Mounted On The I/O Station Of Redundant System
TROUBLESHOOTING 8.3.7 Procedure for Replacing Module mounted on the I/O Station of Redundant System By using the online module change of GX Developer, the module mounted on the MELSECNET/H remote I/O network remote I/O station can be replaced while the redundant system is running .
Page 350: Replacement Of Modules Mounted To Extension Base Unit
TROUBLESHOOTING 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.
Page 351: Tracking Cable Replacement
TROUBLESHOOTING 8.3.9 Tracking Cable Replacement (1) Tracking Cable Replacement The tacking cable cannot be replaced while both systems are running. After powering off the standby system (or keeping the standby system CPU module reset), replace the tracking cable. The standby system can be powered off or reset while the redundant system is running.
Page 352 TROUBLESHOOTING (2) Replacement Procedure The procedure of replacing the tracking cable is shown in the Diagram 8.36. Start Power OFF the Standby System Power off the standby system. (Or, set the RESET/L.CLR switch to the RESET position (reset). Tacking Cable Replacement Disconnect the tracking cable from the control system CPU module.
Page 353: Replacement Procedures Of Extension Cable
TROUBLESHOOTING 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.
Page 354: Chapter9 Processing Time For Redundant Systems
PROCESSING TIME FOR REDUNDANT SYSTEMS CHAPTER9 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).
Page 355: Extension Of Scan Time Due To Tracking
PROCESSING TIME FOR REDUNDANT SYSTEMS 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. Table9.1 Extension of Scam Time due to Tracking Tracking Mode Scan Time Extension Time (ms) Extension of Scam Time Sequence...
Page 356 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) :Tracking Data Preparation Time Tra1 to Tra4 :Transfer Data Processing Time Shown in Table9.2 Table9.2 Processing Times of Tra1 to Tra4 Transfer Data...
Page 357 PROCESSING TIME FOR REDUNDANT SYSTEMS Table9.3 Counting Value of D1 to D4, E1 to E4, F1 to F3, and K1 to K11 System Counting Symbol Content Number Value Symbol Number of Tracking Device Points outside of Index Register 0.09 Number of Tracking Device Points for Index Register 0.15 Number of Tracking Device Points for Standard RAM File 0.09...
Page 358 PROCESSING TIME FOR REDUNDANT SYSTEMS (2) Tracking Processing Time (Trb) Tracking processing time is calculated as shown below. Trb = 0.26 x 10 x (N1 + N2 + N3 + N4) (ms) :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...
Page 359: System Switching Time
PROCESSING TIME FOR REDUNDANT SYSTEMS 9.2 System Switching Time System switching time is the time required from detection of the switching condition for the control system to the start of the new control system CPU's control. Calculate the system switching time using the following expression. Tsw = + T m + Trc (ms) Tsw : System Switching time...
Page 360 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) : Tracking data preparation time : Processing time for transfer data shown in Trc1 to Trc4 Table9.5 Table9.5 Processing Times of Tra1 to Tra4...
Page 361 PROCESSING TIME FOR REDUNDANT SYSTEMS Table9.6 Counting Value of D1 to D4, E1 to E4, F1 to F3, and K1 to K11 System Counting Symbol Content Number Value Symbol Number of Tracking Device Points outside of Index Register 0.09 Number of Tracking Device Points for Index Register 0.15 Number of Tracking Device Points for Standard RAM File 0.09...
Page 362: Appendices
APPENDICES APPENDICES 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 QnPRHCPU Redundant System Q4ARCPU Redundant System Internal device 48k Word Setting Time Internal device 48k Word Setting Time Synchronized Tracking Mode: 41 ms Tracking Time...
Page 363 APPENDICES Table App.1 Comparison of Q4ARCPU and QnPRHCPU Redundant Systems (Continued) Item QnPRHCPU Redundant System Q4ARCPU Redundant System <<First 5 digits of serial No. is "09011" or earlier>> Modules for the expanded system are mounted to MELSECNET/H remote I/O station. [Restrictions on Mounting Modules on Remote I/O Stations] •...
Page 364 APPENDICES Table App.1 Comparison of Q4ARCPU and QnPRHCPU Redundant Systems (Continued) Item QnPRHCPU Redundant System Q4ARCPU Redundant System Applicable Connection CPU Direct Applicable (Communication with the CPU module Applicable Connection connected to the GOT only.) Computer Link Applicable Connection MELSECNET/ H Remote I/O Applicable (N/A for extension base unit) Station...
Page 365 APPENDICES Table App.1 Comparison of Q4ARCPU and QnPRHCPU Redundant Systems (Continued) Item QnPRHCPU Redundant System Q4ARCPU Redundant System Instruction Restrictions Instructions shown in Table App.2 are inapplicable Special Relay Some special relays are different. Special Register Some special registers are different. A-compatible Special Must be changed to a special relay applicable for Applicable...
Page 366: Appendix 2 Comparison Of Qn(H)Cpu And Qnprhcpu
APPENDICES Appendix 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 –...
Page 367 APPENDICES Table App.3 Comparison of Qn(H)CPU and QnPRHCPU (Continuation) Item QnPRHCPU QnHCPU <<First 5 digits of serial No. is "09011" or earlier>> Modules for the expanded system are mounted to MELSECNET/H remote I/O station. [Restrictions on Mounting Modules on Remote I/O Stations] •...
Page 368 APPENDICES Table App.3 Comparison of Qn(H)CPU and QnPRHCPU (Continuation) Item QnPRHCPU QnHCPU Multi CPU System Applicable Single CPU System Applicable (Debug mode only) Applicable Bus Connection Applicable CPU Direct Applicable (Communication with the CPU module connected to Applicable Connection the GOT only) Computer Link Applicable Connection...
Page 369 APPENDICES Table App.4 Instructions Inapplicable for QnPRHCPU Instruction Instruction Instruction Name Instruction Name symbol symbol PLOADP Program Load from Memory Card PLSY Pulse Output PUNLOADP Program Unload from Memory Card Pulse Width Modulation PSWAP Load + Unload Matrix input Print ASCII code S.TO Write To Host Station CPU Shared Memory Print Comments...
Page 370: Appendix 3 Comparison Of Qnphcpu And Qnprhcpu
APPENDICES 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. Internal device 48 k word setting time Scan Time Performance •...
Page 371 APPENDICES Table App.6 Comparison of QnPHCPU and QnPRHCPU (Continued) Item QnPRHCPU QnPHCPU <<First 5 digits of serial No. is "09011" or earlier>> Modules for the expanded system are mounted to MELSECNET/H remote I/O station. [Restrictions on Mounting Modules on Remote I/O Stations] •...
Page 372 APPENDICES Table App.6 Comparison of QnPHCPU and QnPRHCPU (Continued) Item QnPRHCPU QnPHCPU Multi CPU System Applicable Single CPU System Applicable (Debug mode only) Applicable Applicable Connection CPU Direct Applicable (Communication with the CPU module Applicable Connection connected to the GOT only) Computer Link Applicable Connection...
Page 373 APPENDICES Table App.7 Instructions Inapplicable for QnPRHCPU Instruction Instruction Instruction Name Instruction Name Symbol Symbol PLOADP Program Load from Memory Card PLSY Pulse Output PUNLOADP Program Unload from Memory Card Pulse Width Modulation PSWAP Load + Unload Matrix Input Print ASCII code S.TO Write To Host Station CPU Shared Memory Print Comments...
Page 374: Appendix 4 Sample Programs When Using Cc-Link
APPENDICES 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.
Page 375: Appendix 4.3 Devices Used In Programs
APPENDICES 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. Table App.10 CPU Module Devices Device Number Application Remarks SM400 Always On SM402 ON for 1 scan only after RUN SM1515...
Page 376 APPENDICES (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 devices and refresh ranges for the system in Appendix 4.1 (using 5 stations) are shown in Table App.12.
Page 377: Appendix 4.4 Parameter Settings
APPENDICES Appendix 4.4 Parameter Settings The PLC parameters and network parameters for using the sample program are shown here. (1) Program Settings The program settings of the PLC parameter settings are shown in Diagram App.2. Set "MAIN" as a number lower than "CHANGE" in program settings. Diagram App.2 Program Setting Screen Appendix 4 Sample Programs when Using CC-Link - 16...
Page 378 APPENDICES (2) Tracking Settings Make the settings so that the remote output (Y1000 to Y109F) and remote register (W1100 to W1113) will be tracked in the tracking settings of the redundant parameter settings. Diagram App.3 Tracking Setting Screen - 17 Appendix 4 Sample Programs when Using CC-Link Appendix 4.4 Parameter Settings...
Page 379 APPENDICES (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. 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.
Page 380 APPENDICES 6) Special Relay (SB) Set the special relay (SB) refresh device to SB400, "Special relay (SB)". 7) Special Register (SW) Set the special register (SB) refresh device to SW400, "Special register (SW)". 8) Retry Count Use the retry count for communication errors to "3 (Default)". 9) Automatic Reconnection Station Number Use 1 link scan for return to system, set at "1(Default)".
Page 381: Appendix 4.5 Sample Program
APPENDICES Appendix 4.5 Sample Program (1) When the QJ61BT11N’s serial No. (first 5 digits) is "07112" or later (a) Sample Program Name: CHANGE 1) Sample program overview flow CHANGE Set I41 to be valid. Forcibly change the system that (Step 0 to 11) communicates with the CC-Link.
Page 382 APPENDICES 2) Sample Program Adds I41 to the allowable interrupt defaults (I0 to I31, I48 to I255). 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).
Page 383 APPENDICES (b) Sample Program Name: MAIN 1) Sample program overview flow MAIN Turn the enable control program execution flag ON. (Step 0 to 1) Control the CC-Link. (Step 2 to 18) Diagram App.8 Sample program overview flow 2) Sample program Set enable control program execute flag to ON.
Page 384 APPENDICES (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 Set I41 to be valid. Forcibly change the system that (Step 0 to 11) communicates with the CC-Link. (Step 71 to 73) Initialize devices at the time of system switching.
Page 385 APPENDICES 2) Sample Program Adds I41 to the allowable interrupt defaults (I0 to I31, I48 to I255). Set CC-Link forced master switching flag to OFF. Set control program execution flag to OFF. Set system switching execution flag to ON. Set System B first startup system switching flag to OFF.
Page 386 APPENDICES (b) Sample Program Name: MAIN 1) Sample program overview flow MAIN Turn the enable control program execution flag ON. (Step 0 to 1) Control the CC-Link. (Step 2 to 18) Diagram App.12 Sample program overview flow 2) Sample program Set enable control program execute flag to ON.
Page 387: Appendix 5 Method For Starting Up The Previous Control System
APPENDICES Appendix 5 Method for Starting up the Previous Control System When both systems are simultaneously powered on, or when the reset switches of both system CPU modules are simultaneously set to neutral position in a redundant system, the redundant system will start up with system A as the control system. Even when the power supplies for both systems go off temporarily due to a power failure while system B is operating as the control system, system A will start up as the control system when the power supplies of both systems are turned ON.
Page 388 APPENDICES 2) Power supplies of both systems are temporarily OFF because of a power failure, etc. System A System B Tracking cable Power ON Power ON 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.
Page 389 APPENDICES POINT Create a system switching program while paying attention to the following points. • Turn on the special relay, "Manual System Switching Enabled Flag" (SM1592) by executing SP.CONTSW instruction. An "OPERATION ERROR (error code: 4120)" will occur if the SP.CONTSW instruction is executed while SM1592 is OFF.
Page 390 APPENDICES (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...
Page 391 APPENDICES (b) CC-Link master module is mounted on the extension base unit. [System Configuration] System A System B Tracking cable CC-Link master modules Extension cable Diagram App.21 System configuration when CC-Link master module is mounted on the extension base unit [Program Example] (The I/O number assigned to CC-Link master module is from X100 to 11F.) SM1519...
Page 392 APPENDICES POINT 1. If CC-Link system master/local modules are mounted on the main base unit, system B cannot be started up as the control system. Start up system A as the control system. 2. If CC-Link system master module is mounted on the main base unit, system B cannot start as the control system.
Page 393 APPENDICES 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.
Page 394: Appendix 6 Precautions For Using Serial Communication Module
APPENDICES 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.
Page 395 APPENDICES (c) Specification of head address/area size of send area/receive area The following shows the device and buffer memory used in the sample program of specifying the head address and area size. 1) I/O signal Table.App 16 List of I/O Signal I/O signal Signal name Description...
Page 396 APPENDICES 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 H0C00 Sets D0 to head address C00 MOVP H100 Sets D1 to buffer memory length 100 H0A2 Writes send area setting value.
Page 397 APPENDICES (2) When clearing receive data without stopping the send processing in nonprocedural protocol The following shows the device and buffer memory used in the sample program of clearing receive data. (a) Device of programmable controller CPU Table.App 18 Device Used in the Program Device No.
Page 398 APPENDICES The program example of clearing receive data is shown in Diagram App.26. (For the I/O signal is X/Y80 to X/Y9F) Accepts the receive data clear request. M11 M12 Requests the receive H0A8 data clear. Turns ON the receive data clear completion flag. Reads the receive FROM H0A8...
Page 399: Appendix 6.2 Uini Instruction
APPENDICES 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 Mode switching request clear command ON: Mode switching request clear Mode switching command ON: Mode switching...
Page 400 APPENDICES (a) Switching mode No. specification area (Address: 90 , 130 The mode No. after switching (0001 to 0007 , 00FF ) is written to this area. Buffer memory address 90 /130 (Default 0000 0001 : MC protocol (Format 1) 0002 : MC protocol (Format 2) 0003...
Page 401 APPENDICES The program example for mode switching is shown in Diagram App.27. (For the I/O signal is X/Y80 to X/Y9F) Changes operation mode into MC protocol format 1 Sets transmission specification H85B0 D1 Writes mode switching specification contents to buffer memory Sets mode switching request Resets mode switching request signal FROM H8...
Page 402: Appendix 6.3 Input Instruction
APPENDICES 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) I/O signal Table.App 25 List of I/O Signal I/O signal Signal name Description CH1 side CH2 side Reception data read request...
Page 403: Appendix 6.4 Pute Instruction
APPENDICES Appendix 6.4 PUTE Instruction The following shows the device and buffer memory used in the sample program of registering the user registration frame. (1) Device of programmable controller CPU Table.App 27 Device Used in the Program Device No. Application Remarks Register request command ON: Register request...
Page 404 APPENDICES 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) Requests registration Sets registration request H3E8 Sets frame No. to be registered Sets the number of data byte to be registered H3946 H3030...
Page 405: Appendix 6.5 Gete Instruction
APPENDICES Appendix 6.5 GETE Instruction The following shows the device and buffer memory used in the sample program of reading the user registration frame. (1) Device of programmable controller CPU Table.App 30 Device Used in the Program Device No. Application Remarks Read command ON: Read command...
Page 406 APPENDICES 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) Pulse-outputs read command Sets the read request H3EB Sets the frame No. to be read Writes read command etc. Sets read flag Turns ON the read request signal.
Page 407: Appendix 6.6 Ondemand Instruction
APPENDICES Appendix 6.6 ONDEMAND Instruction The following shows the device and buffer memory used in the sample program of sending data by the on-demand function. (1) Device of programmable controller CPU Table.App 33 Device Used in the Program Device No. Application Remarks Transmission command...
Page 408 APPENDICES 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) Initial setting program for Q series C24(N) Writing is not required when send TOP H8 data is set in units of bytes/words Pulse-outputs send command MOV H1234 MOV H5678...
Page 409: Appendix 6.7 Output Instruction
APPENDICES Appendix 6.7 OUTPUT Instruction The following shows the device and buffer memory used in the sample program of sending data by the nonprocedural protocol communication. (1) Device of programmable controller CPU Table.App 36 Device Used in the Program Device No. Application Remarks Transmission command...
Page 410 APPENDICES 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) X80 X81 $MOV "abcdefg" Sets send data and number MOVP H0A0D D15 of send data MOVP Writes the number of send data and H400...
Page 411: Appendix 6.8 Prr Instruction
APPENDICES Appendix 6.8 PRR Instruction The following shows the device and buffer memory used in the sample program of sending data by the user registration frame of the nonprocedural protocol communication. (1) Device of programmable controller CPU Table.App 39 Device Used in the Program Device No.
Page 412 APPENDICES 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) X9E X9F X80 X81 Y80 MOV K4 Sets the send data and the number of send data. MOV H1234 D1 MOV H56AB D2 MOV H0...
Page 413: Appendix 6.9 Bidout Instruction
APPENDICES Appendix 6.9 BIDOUT Instruction The following shows the device and buffer memory used in the sample program of sending data by the bidirectional protocol communication. (1) Device of programmable controller CPU Table.App 42 Device Used in the Program Device No. Application Remarks Transmission command...
Page 414 APPENDICES 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) X80 X81 $MOV "ABCDEFG" MOVP H0A0D D15 Sets the send data and the number of send data. MOVP Writes the send data and the number of send H400...
Page 415: Appendix 6.10 Bidin Instruction
APPENDICES Appendix 6.10 BIDIN Instruction The following shows the device and buffer memory used in the sample program of receiving data by the bidirectional protocol communication. (1) Device of programmable controller CPU Table.App 45 Device Used in the Program Device No. Application Remarks Error code read command...
Page 416: Appendix 7 Cautions On Communications Made Via Module On Extension Base Unit
APPENDICES Appendix 7 Cautions on Communications Made via Module on Extension Base Unit (1) MC protocol frames available for communications Use QnA-compatible 2C/3C/4C frame, QnA-compatible 3E frame, or 4E frame for the access. (2) 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...
Page 417 APPENDICES (3) System switching during communication made via a module on an extension base unit If system switching occurs during communication made via a module on an extension base unit by MC protocol or a dedicated instruction, both the old and new control systems may not be able to respond, and this may cause a communication timeout.
Page 418: Index
INDEX CONTROL EXE. ••••••••••••••••••••••••••••••••••••••••5-34 Control system ••••••••••••••••••••••••••••••••••••• 1-22,5-5 Applicable devices ••••••••••••••••••••••••••••••••••••• 2-13 Control/standby status flag (SM1515) ••••••••••••••• 5-7 Applicable software •••••••••••••••••••••••••••••••••••• 2-13 Control/standby status flag (SM1516) ••••••••••••••• 5-7 Applicable software packages ••••••••••••••••••••••• 2-17 Asynchronized tracking mode•••••••••••••••••••••••• 5-93 Automatic system switching •••••••••••••••••••••••••• 5-35 System switching requested by the network module Debug mode •••••••••••••••••••••••••••••••••••••••••••••5-13 ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••...
Page 419 Memory card setting status consistency check ••• 5-23 Redundant type extension base unit•••••••••••••••• 1-21 Memory copy from control system to standby system Remote I/O network•••••••••••••••••••••••••••••••••••• 6-17 ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 5-111 Remote latch clear ••••••••••••••••••••••••••••••••••• 5-131 Memory copy from control system to standby system Remote operation ••••••••••••••••••••••••••••••••••••...
Page 420 SM609 ••••••••••••••••••••••••••••••••••••••••••••••••• 5-24 Standby system error detection disable flag at The case where the "BACKUP" LED of the CPU system switching••••••••••••••••••••••••••••••••••••• 5-53 module is on (red) ••••••••••••••••••••••••••••••••••••••• 8-5 System switching enable/disable flag from network The case where the "MODE" LED does not turn on module •••••••••••••••••••••••••••••••••••••••••••••••••...
Page 421 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.
Page 422 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.

This manual is also suitable for:

Q25prhcpu

Mitsubishi Q12PRHCPU User Manual

Chapter1 Overview

Chapter2 System Configuration

Chapter3 Tracking Cable

Chapter4 Procedure For Starting up Aredundant System

Chapter5 Redundant System Functions

Chapter6 Redundant System Networks

Chapter7 Programming Cautions

Chapter8 Troubleshooting

Chapter9 Processing Time for Redundant Systems

Appendices

Appendix 1 Comparison of Q4ARCPU and Qnprhcpu

Appendix 2 Comparison of Qn(H)CPU and Qnprhcpu

Appendix 3 Comparison of Qnphcpu and Qnprhcpu

Appendix 4 Sample Programs When Using CC-Link

Appendix 4.1 Sample Program System Configuration

Appendix 4.2 Sample Program Names

Appendix 4.3 Devices Used in Programs

Appendix 4.4 Parameter Settings

Appendix 4.5 Sample Program

Appendix 5 Method for Starting up the Previous Control System

Appendix 6 Precautions for Using Serial Communication Module

Appendix

Appendix 6.2 UINI Instruction

Appendix 6.3 INPUT Instruction

Appendix 6.4 PUTE Instruction

Appendix 6.5 GETE Instruction

Appendix 6.6 ONDEMAND Instruction

Appendix 6.7 OUTPUT Instruction

Appendix 6.8 PRR Instruction

Appendix 6.9 BIDOUT Instruction

Appendix 6.10 BIDIN Instruction

Appendix 7 Cautions on Communications Made Via Module on Extension Base Unit

Index

Quick Links

Troubleshooting

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Summary of Contents for Mitsubishi Q12PRHCPU