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Mitsubishi Electric MELSEC iQ-R Series Manual

Online module change.
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MELSEC iQ-R
Online Module Change Manual

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Table of Contents

   Summary of Contents for Mitsubishi Electric MELSEC iQ-R Series

  • Page 1 MELSEC iQ-R Online Module Change Manual...
  • Page 3: Safety Precautions

    (Read these precautions before using this product.) Before using MELSEC iQ-R series programmable controllers, please read the manuals for the product and the relevant manuals introduced in those manuals carefully, and pay full attention to safety to handle the product correctly.
  • Page 4 MEMO...
  • Page 5: Table Of Contents

    CONTENTS SAFETY PRECAUTIONS ..............1 CONDITIONS OF USE FOR THE PRODUCT .
  • Page 6: Relevant Manuals

    Module User's Manual (Application) remote head module e-Manual [SH-081616ENG] e-Manual refers to the Mitsubishi Electric FA electronic book manuals that can be browsed using a dedicated tool. e-Manual has the following features: • Required information can be cross-searched in multiple manuals.
  • Page 7: Terms

    A backup system in a redundant system Temperature control module The abbreviation for the MELSEC iQ-R series temperature control module Temperature input module A generic term for the MELSEC iQ-R series channel isolated thermocouple input module and channel isolated RTD input module...
  • Page 8: Chapter 1 Overview

    OVERVIEW The online module change function allows users to replace the module mounted on a main base unit or an extension base unit with a new module controlling the system while the power is on (online). The online module change function allows users to replace the module that malfunctioned during control with a module having the same model as that of the malfunctioning module.
  • Page 9 Changing a module directly By setting parameters in advance, the target module can be replaced with a new one without using the engineering tool or external devices. No operations for special relays or special registers are required. Thus, the module can be replaced easily. Engineering tool Ò...
  • Page 10: Chapter 2 System Configuration

    SYSTEM CONFIGURATION This chapter describes the system configuration to perform the online module change. Configuration Devices The following shows the modules and engineering tool that support the online module change. CPU module The online module change can be performed when the system is configured using a Process CPU or SIL2 Process CPU. Remote head module The online module change can be performed when the system is configured using a remote head module.
  • Page 11 Modules that support the online module change The following table lists the modules that support the online module change. Module Model Remarks CPU module extension Redundant function module R6RFM   I/O modules AC input module RX10, RX10-TS, RX28 DC input module RX40C7, RX40C7-TS, RX41C4, RX41C4-TS, RX42C4, RX70C4, RX71C4, RX72C4...
  • Page 12: Restrictions On System Configuration

    Restrictions on System Configuration This section describes the restrictions on the system configuration. • When 'Online module change availability flag' (SM1616) of the CPU module or remote head module is OFF (0), the online module change cannot be performed. Before performing the online module change, check that 'Online module change availability flag' (SM1616) is ON (1).
  • Page 13: Precautions For System Configuration

    Precautions for System Configuration This section describes the precautions for the system configuration. • For the module to be prepared for online module change, check the following in advance: • The new module to be mounted has the same model name as the replacement target module. •...
  • Page 14 MEMO 2 SYSTEM CONFIGURATION 2.3 Precautions for System Configuration...
  • Page 15: Chapter 3 Replacement Procedure

    REPLACEMENT PROCEDURE This chapter describes the procedures of online module change. Specifications This section describes the specifications of the online module change function. • Here are the application and features of each method of online module change. Replacement method Application Merit Demerit Changing a module by controlling...
  • Page 16 Overall flow Follow the following flow in each online module change: ■Changing a module by controlling special relays and special registers Checks before replacement ( Page 30 Checks before replacement) Module selection ( Page 33 Module selection) Module change activation ( Page 34 Module change activation) Module removal (...
  • Page 17 LED status The following shows each LED status indicated at each step in online module change. ■Changing a module by controlling special relays and special registers [When the system is configured using a CPU module] Step in online module change Change in 'Online module LED status on CPU module LED status on target...
  • Page 18 [When the system is configured using a remote head module] Step in online module change Change in 'Online module LED status on remote head module LED status on target changing status' (SD1617) module RUN LED ERR LED RUN LED Checks before replacement 0 ...
  • Page 19 ■Changing a module directly [When the system is configured using a CPU module] Step in online module change Change in 'Online module LED status on CPU module LED status on target changing status' (SD1617) module READY LED ERROR LED RUN LED Checks before replacement 0 ...
  • Page 20 [When the system is configured using a remote head module] Step in online module change Change in 'Online module LED status on remote head module LED status on target changing status' (SD1617) module RUN LED ERR LED RUN LED Checks before replacement 0 ...
  • Page 21 Access to the module The following shows the method for accessing each online module. ■Changing a module by controlling special relays and special registers • I/O modules : Executed, : Not executed Procedure I/O refresh Direct access FROM/TO Instruction using the Device Monitor instruction...
  • Page 22 ■Changing a module directly • I/O modules : Executed, : Not executed Procedure I/O refresh Direct access FROM/TO Instruction using the Device Monitor instruction module access test Input (X) Output Input Output device (DX) (DY)      ...
  • Page 23: Specifications Of The Redundant System

    Specifications of the redundant system This section describes the specifications of online module change for the redundant system. • Both in backup mode and in separate mode, online module change is permitted. • Both in the control system and in the standby system, online module change is permitted. •...
  • Page 24: Specifications Of Each Module

    Specifications of each module This section describes the specifications of online module change for each module. Redundant function modules ■Precautions • Performing online module change in the control system and the standby system simultaneously is not possible. • After 'Module remove request flag' (SM1602) is turned on, the communication via the redundant function module stops until 'Module recognition request flag' (SM1606) is turned on.
  • Page 25 D/A converter modules ■Restoration of the user range setting Setting the following item to "Enable" allows the module-specific backup parameter (offset/gain value) in the CPU module or remote head module to be automatically restored upon module recognition. Thus, even without the use of dedicated instructions or other means, a newly replaced D/A converter module operates with the same user range setting as that of the old D/A converter module.
  • Page 26 Temperature control modules ■Q compatible mode A module in operation in Q compatible mode also allows online module change. The newly replaced temperature control module starts up in Q compatible mode. ■Precautions • Even if pre-recorded data are set to the buffer memory in the newly replaced module and control is restarted, the module cannot restart the control in the same control condition.
  • Page 27 Flexible high-speed I/O control module ■Restoration of hardware logic Setting "Hardware logic control auto restoration executed/unexecuted" of the module parameter to "Enable" allows the module-specific backup parameter (hardware logic) in the CPU module to be automatically restored upon module recognition. Thus, a newly replaced flexible high-speed I/O control module operates with the same hardware logic as that of the old flexible high-speed I/O control module, without the hardware logic being written from the configuration tool.
  • Page 28 MES interface module ■Module-specific backup parameter The module-specific backup parameter is not provided, and thus no data is backed up. ■Precautions Stop all communications of the MES Interface Function Configuration Tool to the module before executing the online module change, because when the online module change is executed, communication with the MES Interface Function Configuration Tool is also stopped.
  • Page 29: Restrictions On Replacement Procedures

    Restrictions on Replacement Procedures • When a module is removed directly while a module dedicated instruction is active, the completion status of the module dedicated instruction does not become Completed with an error. • Replace one module at a time. Do not replace any other module during online module change. Doing so does not guarantee the operation of the mounted module.
  • Page 30: Precautions For Replacement Procedures

    Precautions for Replacement Procedures • Before online module change, make sure that the systems outside the programmable controllers are free from malfunction. • The precautions for mounting and removing a module are the same as the ones for mounting and removing a module on and from a base unit.
  • Page 31: Changing A Module By Controlling Special Relays And Special Registers

    Changing a Module by Controlling Special Relays and Special Registers This section describes the method to replace a module using special relays and special registers. To replace a module using special relays and special registers, use the following special relays or special registers. SM number, SD number Name SM1600...
  • Page 32 Checks before replacement The following shows the check procedure before replacement. In this procedure, stop the control of the online module change target module for safe online module change. ■Redundant function modules Check that a redundant function module in the other system is not being changed online. ■I/O modules Stop all the outputs (Y) and inputs (X).
  • Page 33 ■Temperature control modules (for the R60TCTRT2TT2) Set Stop (0) in 'PID continuation flag' (Un\G306) of all the channels with an external device (such as a GOT). Turn on and off 'Setting/operation mode command' (Y1). Turn off all the Y signals. Check that the PID control is stopped with 'Setting/operation mode status' (X1).
  • Page 34 ■MES interface module Access to the SD memory card is stopped by using 'File access stop request' (Y3) or SD memory card access control switch. Access to the MES interface module from the MES Interface Function Configuration Tool will stop. ■High speed data logger module Stop file access process is executed by using the High Speed Data Logger Module Configuration Tool, the SD memory card access control switch, or 'File access stop request' (Y2).
  • Page 35 Module selection The following shows the procedure to select a module. In this procedure, select an online module change target module. Module selection Set the position of the replacement target module in 'Module selection (base unit No.)' (SD1600). Set the position of the replacement target module in 'Module selection (slot No.)' (SD1601).
  • Page 36 Module change activation The following shows the procedure for module change activation. In this procedure, set the target module to be ready for online module change. Module change activation Turn on 'Module removal request flag' (SM1602). Module removal ready (4) is stored in 'Online module change progress status' *1*2...
  • Page 37 Module removal The following shows the procedure to remove the module. In this procedure, remove the target module from the base unit. Module removal Remove the terminal block and connectors from the replacement target module. Remove the replacement target module from the base unit.
  • Page 38 Module mounting The following shows the procedure to mount the module. In this procedure, mount the target module on the base unit. Module mounting Mount a new module on the same slot. Connect the terminal block and connecters to the new module. Do not supply external power supply to the module here.
  • Page 39 Module recognition The following shows the procedure to recognize the module. In this procedure, make the system recognize the new module so that the system can control it. Module recognition Turn on 'Module recognition request flag' (SM1606). Module recognition completion (8) is stored in 'Online module change progress status' (SD1617).
  • Page 40 ■Initial setting for high-speed counter modules 'Module READY' (X0) turns on when the RUN LED on the high-speed counter module turns on. To execute the initial setting using a program, implement an interlock in the program as follows. Do not design a program that executes the initial setting only in one scan after the CPU module has started running.
  • Page 41 Module control start The following shows the procedure to restart the module control. In this procedure, complete the online module change and restart the control of the new module. Before restarting the control of the module, check the following precautions. ■Precautions •...
  • Page 42 ■I/O modules with diagnostic functions Check that 'Module READY' (X1F) is off. 'Module READY' (X1F) turns off when the READY LED on the CPU module (RUN LED on the remote head module) that is flashing (at 400ms intervals) turns on. To execute the initial setting using a program, design the program so that the initial setting is executed when 'Module READY' (X1F) turns off.
  • Page 43 ■Positioning modules (for the RD75P4) Check that Module access flag [X1] is on. Module access flag [X1] turns on when the READY LED on the CPU module (RUN LED on the remote head module) that is flashing (at 400ms intervals) turns on. At this time, execute the initial setting or home position return as necessary. To execute the initial setting or home position return using a program, design the program so that the initial setting or home position return is executed when Module access flag [X1] turns on.
  • Page 44 Cancel of module selection Module selection for an online module change can be canceled before the online module change is started. When an incorrect module has been selected as the replacement target module, the selection can be canceled by turning on 'Module selection cancel request flag' (SM1615) before the module change is started.
  • Page 45: Changing A Module Directly

    Changing a Module Directly This section describes the method to change a module directly. The direct change is not available for redundant function modules as a method of the online module change. Presettings To perform a direct online module change, "Direct change setting" must be set to "Enable" in advance. Navigation window ...
  • Page 46 Module removal The following shows the procedure to remove the module. In this procedure, remove the target module from the base unit. This procedure is common among all the modules. In direct change, when a module is removed, input values from the module to the CPU module or remote head module may become undefined.
  • Page 47 Module mounting The following shows the procedure to mount the module. In this procedure, mount the target module on the base unit. This procedure is common among all the modules. In direct change, control is immediately started after the module is mounted. Thus, after mounting a terminal block and connectors to the module, check that the system does not malfunction and mount the module.
  • Page 48 Module recognition The following shows the procedure to recognize the module. The new module is automatically recognized by the system. In this procedure, check if the module has been normally recognized. This procedure is common among all the modules. Module recognition The RUN LED of the newly-mounted module is on.
  • Page 49 Module control start The following shows the procedure to restart the module control. In this procedure, complete the online module change and restart the control of the new module. Before restarting the control of the module, check the following precautions. ■Precautions •...
  • Page 50 ■A/D converter modules (for the R60AD4), D/A converter modules (for the R60DA4), temperature input modules (for the R60TD8-G), temperature control modules (for the R60TCTRT2TT2) Check that 'Module READY' (X0) is on. After module recognition, 'Module READY' (X0) turns on. To execute the initial setting using a program, design the program so that the initial setting is executed when 'Module READY' (X0) turns on.
  • Page 51 ■Positioning modules (for the RD75P4) Check that Module access flag [X1] is on. After module recognition, Module access flag [X1] turns on. At this time, execute the initial setting or home position return as necessary. To execute the initial setting or home position return using a program, design the program so that the initial setting or home position return is executed when Module access flag [X1] turns on.
  • Page 52: Chapter 4 Troubleshooting

    TROUBLESHOOTING This chapter describes the troubleshooting related to online module change. Error Processing and Recovery Methods This section describes how errors are processed and informed, and how to recover from the errors if there is an abnormality in online module change. For the errors relating to online module change, perform a check according to the type of error in the description below.
  • Page 53: Troubleshooting By Symptom

    Troubleshooting by Symptom This section describes the troubleshooting by symptom. For the replacement by means of control of special relays and special registers The troubleshooting when a module is replaced controlling special relays and special registers is shown in the following table for each step in online module change.
  • Page 54 Procedure Symptom Check item Action Module After 'Module recognition request Is 'Online module change error When 'Online module change error flag' (SM1618) is on, recognition flag' (SM1606) is turned on, flag' (SM1618) on? take the corrective actions corresponding to the error 'Online module changing status' code stored in 'Online module change error code' (SD1617) does not become...
  • Page 55 MEMO 4 TROUBLESHOOTING 4.2 Troubleshooting by Symptom...
  • Page 56: Index

    INDEX ..... 5 ......5 A/D converter module Separate mode .
  • Page 57 MEMO...
  • Page 58: Revisions

    Japanese manual number: SH-081500-J This manual confers no industrial property 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 59: Warranty

    WARRANTY Please confirm the following product warranty details before using this product. 1. Gratis Warranty Term and Gratis Warranty Range If any faults or defects (hereinafter "Failure") found to be the responsibility of Mitsubishi occurs during use of the product within the gratis warranty term, the product shall be repaired at no cost via the sales representative or Mitsubishi Service Company.
  • Page 60: Trademarks

    TRADEMARKS Ethernet is a registered trademark of Fuji Xerox Co., Ltd. in Japan. The company names, system names and product names mentioned in this manual are either registered trademarks or trademarks of their respective companies.   In some cases, trademark symbols such as ' ' or ' ' are not specified in this manual.
  • Page 62 SH(NA)-081501ENG-J(1804)MEE MODEL: R-OMC-E MODEL CODE: 13JX35 HEAD OFFICE : TOKYO BUILDING, 2-7-3 MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN NAGOYA WORKS : 1-14 , YADA-MINAMI 5-CHOME , HIGASHI-KU, NAGOYA , JAPAN When exported from Japan, this manual does not require application to the Ministry of Economy, Trade and Industry for service transaction permission.

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