Mitsubishi Electric MELSEC iQ-R-R04CPU

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30 MAINTENANCE AND INSPECTION FOR A REDUNDANT SYSTEM

30.1 Module Replacement in the Redundant System

MEMO

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Default Chapter3
- Safety Precautions3
- Conditions of Use for the Product16
- Introduction18
- Table of Contents19
- Relevant Manuals35
- Terms36
Part 1 Cpu Module Operation39
Chapter 1 Running a Program40
Scan Configuration40
- Initial Processing (When Powered on or Switched to RUN)40
- I/O Refresh41
- Program Operation41
- END Processing41
Scan Time42
- Initial Scan Time42
- Constant Scan43
- Device/Label Access Service Processing Setting45
Data Communication and I/O Processing49
- Data Communication49
- I/O Processing and Response Delay49
- Refresh Mode50
- Direct Mode52
Program Flow54
Program Execution Type55
- Initial Execution Type Program55
- Scan Execution Type Program56
- Fixed Scan Execution Type Program56
- Event Execution Type Program61
- Standby Type Program65
- Execution Type Change66
- Group Setting for Refresh67
Subroutine Program68
Interrupt Program69
- Interrupt Period Setting79
- Interrupt Enabled During Instruction Execution79
- Processing at Interrupt Program Startup80
- Multiple Interrupt Function83
Chapter 2 Cpu Module Operation Processing89
Operation Processing by Operating Status89
Operation Processing When Operating Status Is Changed90
- Output Mode at Operating Status Change (STOP to RUN)91
Operation Processing at Momentary Power Failure93
Chapter 3 Memory Configuration of the Cpu Module94
Memory Configuration94
- Program Memory/Program Cache Memory95
- Device/Label Memory96
- Data Memory100
- Function Memory100
- Refresh Memory100
- CPU Buffer Memory100
- Signal Flow Memory101
- SD Memory Card101
File Size Unit in Memory102
Memory Operation103
- Initialization and Value Clear103
Files104
- File Types and Storage Memory104
- File Operation Available106
- File Size107
Part 2 Functions109
Chapter 4 Clock Function110
Time Setting110
- Clock Data110
- Changing the Clock Data110
- Reading the Clock Data111
- Precautions on the Clock Data111
Setting Time Zone112
Daylight Saving Time Function113
- Daylight Saving Time Setting113
- Timing of Daylight Saving Time Adjustment114
- Daylight Saving Time Function Operation Check115
- Operation of Other Functions Using Clock Data During Daylight Saving Time115
- Precautions115
System Clock116
- Special Relay Used for System Clock116
- Special Register Used for System Clock116
Chapter 5 Writing Data to the Cpu Module117
Writing Data to the Programmable Controller117
Online Change117
- Online Change (Ladder Block)117
- File Batch Online Change121
Precautions122
Chapter 6 Ras Functions127
Scan Monitoring Function127
- Scan Time Monitoring Time Setting127
- Watchdog Timer Reset127
- Precautions128
Self-Diagnostics Function129
- Self-Diagnostics Timing129
- Check Method of Error129
- CPU Module Operation Upon Error Detection Setting130
- Error Detection Invalidation Setting134
Error Clear135
Event History Function138
- Event History Setting138
- Logging of the Event History139
- Viewing the Event History141
- Clearing the Event History141
- Precautions142
Program Cache Memory Auto Recovery Function142
Chapter 7 Remote Operation143
Remote RUN/STOP143
- Executing Method143
- Precautions144
Remote PAUSE144
- Executing Method144
Setting RUN-PAUSE Contacts145
Remote RESET145
- Enabling Remote RESET145
- Executing Method145
Chapter 8 Boot Operation146
Boot Operation Procedure146
Specifiable File Types147
Allowed Maximum Number of Boot Files147
Configuring the Boot Setting148
Operation When Security Functions Are Enabled149
- When a Security Key Is Set149
- When a File Password Is Set149
Precautions149
Chapter 9 Monitor Function150
Real-Time Monitor Function150
Chapter 10 Test Function152
External Input/Output Forced On/Off Function152
Device Test with Execution Conditions159
Chapter 11 Data Logging Function172
Data to be Collected173
- Number of Data Points173
- Data Type173
Data Collection Conditions175
- Each Scan175
- Time Specification175
- Interrupt Occurrence176
- Condition Specification177
Logging Type180
- Operating Procedure for Continuous Logging180
- Operating Procedure for Trigger Logging181
Data Logging File185
- Storage Format of Data Logging Files185
- Storage Location of Data Logging Files185
States of the Data Logging Function186
- Data Logging States186
- LED Status187
Steps until the Collected Data Is Saved188
- Internal Buffer190
- Switching to a Storage File192
Missing Data195
- Conditions under Which Missing Data Occurs195
Data Logging File Transfer (Auto Transfer to FTP Server)196
Data Logging File Transfer to Data Memory204
Setting Behavior at the Time of Transition to RUN205
Auto Logging206
SD Memory Card Replacement208
SD Memory Card Life When the Data Logging Function Is Used209
Errors Generated During Data Logging210
Special Relay and Special Register Used by the Data Logging Function210
Precautions to Take When Using the Data Logging Function211
Chapter 12 Debug Function223
Memory Dump Function223
- Object Data224
- Trigger Condition224
- Procedure for Memory Dump226
- Flow of Data Collection227
- Memory Dump File228
- States of the Memory Dump Function229
- Sizes of Files Used for the Memory Dump Function230
- Special Relay and Special Register Used in the Memory Dump Function231
- Precautions for the Memory Dump Function231
Chapter 13 Database Function234
Specifications235
Database Access Instruction238
- Usage Procedure238
- Creating Unicode Text Files239
- Transactions for Databases242
- Folder Configuration of Databases242
- Timing of Database Update243
- Precautions243
CPU Module Database Access (from External Device) Function244
- Usage Procedure244
- Built-In Database Access Setting246
- Creating a Database247
- Adding a Database to the ODBC Data Source248
- Application Example250
- Precautions261
Chapter 14 Pid Control/Process Control Function264
PID Control Function264
Process Control Function265
- Process Control by Using Process Control Function Blocks265
- Process Control by Using Process Control Instructions266
Chapter 15 Cpu Module Data Backup/Restoration Function267
Backup Function272
- Backup Processing Triggered by Turning on SM1351274
- Automatic Backup Using SD944275
- Checking Backup Errors277
- Precautions277
Restoration Function281
- Restoration Processing Triggered by Turning on SM1354283
- Automatic Restoration Using SD955284
- Checking Restoration Errors284
- Precautions285
Chapter 16 Multiple Cpu System Function290
Out-Of-Group I/O Fetch291
- Accessing Controlled Module291
- Accessing Non-Controlled Module291
Operation Settings293
- Stop Setting293
- Synchronous Startup Setting294
- Clock Data297
Multiple CPU Parameter Checking298
Data Communication between CPU Modules299
- Memory to be Used299
- Fixed Scan Communication Setting304
- Error Detection Setting304
- Module-By-Module Data Guarantee305
- Communication through Refresh307
- Communication through Direct Access311
- Data Guarantee by Program314
- Communication between CPU Modules in Error State317
Multiple CPU Synchronous Interrupt318
- Execution Timing319
- Multiple Interrupt319
- Precautions319
Chapter 17 Security Function320
Chapter 18 Sequence Scan Synchronization Sampling Function322
Chapter 19 Label Initialization Function324
Initialization of Labels after Rebuilt All (Reassignment)324
Label Initial Value Reflection Setting326
Chapter 20 Routing Setting328
Setting Method328
Setting Example329
Precautions329
Part 3 Devices, Labels, and Constants331
Chapter 21 Devices332
Device List332
Device Setting333
- Range of Use of Device Points334
User Device335
- Input (X)335
- Output (Y)335
- Internal Relay (M)336
- Latch Relay (L)336
- Link Relay (B)336
- Annunciator (F)336
- Link Special Relay (SB)338
- Edge Relay (V)339
- Step Relay (S)339
- Timer340
- Counter346
- Data Register (D)349
- Link Register (W)349
- Link Special Register (SW)349
System Device350
- Function Device (FX/FY/FD)350
- Special Relay (SM)351
- Special Register (SD)351
Link Direct Device351
- Specification Method351
- Specification Range352
- Difference from Link Refresh352
Module Access Device353
- Precautions354
CPU Buffer Memory Access Device354
- Specification Method354
Index Register (Z/LZ)355
- 16-Bit Index Modification355
- Device for Which Index Modification Can be Performed356
- Index Register Setting356
- Combination of Index Modification357
- Precautions357
File Register (R/ZR)359
- Specification Method359
- Setting File Registers360
- Clearing File Registers361
Refresh Data Register (RD)361
- Refresh Memory Setting361
Nesting (N)362
Pointer (P)363
- Global Pointer363
- Local Pointer364
- Pointer Setting365
Interrupt Pointer (I)365
- Interrupt Factors of the Interrupt Pointer Numbers366
- The Priority for the Interrupt Pointer Numbers and Interrupt Factors366
Network No. Specification Device (J)367
I/O No. Specification Device (U)367
SFC Block Device (BL)367
SFC Transition Device (TR)367
Global Device368
Local Device368
Indirect Specification373
Chapter 22 Labels374
Global Labels374
Local Labels374
Classes375
Data Types376
Arrays379
Structures383
Label Access Setting from External Device385
- Configuration Procedure386
- Label Communication Data Storage Location and Operation at the Time of each Setting Operation386
- File Operation386
Precautions387
Chapter 23 Latch Function389
Latch with Battery389
- Types of Latch389
- Applicable Devices and Labels390
- Setting Latch on Devices391
- Setting Latch on Labels395
- Clearing Latch Range Data395
- Precautions395
Latch with Battery-Less Option Cassette396
- Usage Procedure396
- Precautions398
Chapter 24 Device/Label Initial Value Settings399
Setting Initial Device/Label Values400
- Setting Initial Device Values400
- Setting Initial Label Values401
Applicable Devices/Labels402
Precautions402
Chapter 25 Constants403
Decimal Constant (K)403
Hexadecimal Constant (H)403
Real Constant (E)404
- Setting Range for Real Numbers404
- Processing When Operation Is in Progress404
Character String Constant404
Notation of Constants405
Part 4 When Using the Process Cpu (Redundant Mode)407
Chapter 26 Basic Concept408
System408
System Switching between the Control System and Standby System409
System Consistency Check409
Operation Mode of the Process CPU409
Operation Modes of the Redundant System410
Scan Configuration411
Determination of Control System/Standby System412
- When Starting up both Systems Simultaneously412
- When Starting up One System First413
- When One System Is Started Automatically Even Though a Tracking Communication Error Has Occurred415
- When Starting up the Previous Control System as the Control System420
State Transition of the Redundant System422
Chapter 27 Procedure for Starting up a Redundant System424
Overview424
- Starting up both Systems at a Time424
- Starting up the Systems One by One426
- Precautions on Starting up the System When the Data Logging Function Is Used429
Wiring430
- Wiring the Redundant Function Modules430
- Wiring to the Power Supply Modules in a Redundant System431
Creating a Project432
Connecting a Personal Computer and a CPU Module432
System A/B Settings433
Writing Data to the Programmable Controller435
Monitoring the Program436
Chapter 28 Functions437
Operation Mode Change440
- Switching Procedure440
- Precautions442
System Switching443
- System Switching Method443
- Operation at System Switching448
- Execution Availability of System Switching449
- Check Method of System Switching Information451
- Precautions453
Tracking Transfer456
- Tracking Data457
- Tracking Block and Tracking Trigger460
- Setting Procedure for Tracking Transfer461
- Tracking Transfer Setting462
- Tracking Mode466
- Precautions469
Memory Copy from Control System to Standby System470
- Automatic Memory Copy472
- Memory Copy with the Engineering Tool473
- Memory Copy with the Special Relay and Special Register474
- Precautions476
System Consistency Check477
- File479
- Operating Status480
- Mounting Status of Main Base Unit480
- SD Memory Card480
Program Execution in both Systems481
- Operation of a Program Executed in both Systems483
- Precautions485
Redundant System Operation Setting487
- Standby System Output Setting488
Redundant Function Module Communication Test489
- Execution Procedure of the Module Communication Test489
Constant Scan490
Online Change491
RAS Function492
- Clearing Errors on the Standby System CPU Module from the Control System CPU Module492
Remote Operation493
- Remote RUN, Remote STOP, Remote PAUSE493
- Remote RESET494
- Precautions494
Boot Operation495
External Input/Output Forced On/Off Function496
Data Logging Function500
- Data Logging States500
- LED Status501
- Data Collection Conditions501
- Trigger Logging501
- Switching to a Storage File502
- Writing the Data Logging Setting502
- Auto Logging Function502
SLMP Communication503
Chapter 29 Precautions on Programming504
Instructions Not Available in Redundant System504
- Instructions that Cause Stop Errors504
- Instructions that Need to be Executed Again in a New Control System505
- Instructions Whose Operations Vary Depending on Tracking of the Signal Flow Memory508
- Instructions that Affect the Status of Another Instruction When Executed510
- Instruction that Causes Different Operation Results between the Control System and Standby System510
- Precautions for Using the COM or ZCOM Instruction511
- Precautions for Using the ADRSET Instruction511
Interrupt from Modules512
- System Switching in Backup Mode512
- System Switching in Separate Mode512
- When the Operation Mode Is Switched to the Separate Mode512
- When the Operation Mode Is Switched to the Backup Mode513
Precautions for Using the Annunciator (F)513
Precautions on Timers and Timer Function Blocks514
Precautions on Access to Intelligent Function Module or External Devices515
Precautions on Writing Data from GOT or External Devices517
Precautions on Outputting in the Middle of the Scan517
Chapter 30 Maintenance and Inspection for a Redundant System518
Module Replacement in the Redundant System518
- Replacing a CPU Module519
- Replacing a Power Supply Module521
- Replacing a Redundant Power Supply Module521
- Replacing a Redundant Function Module522
- Replacing I/O Modules522
- Replacing a Network Module523
- Replacing a Main Base Unit523
Part 5 When Using the Safety Cpu525
Chapter 31 Running a Safety Program526
Overview526
Safety Program527
Safety Cycle Time529
- Setting Method529
Safety CPU Operating Status530
- Operation Processing Based on Safety CPU Operating Status530
- Operation Processing When Operating Status of the Safety CPU Changes530
Chapter 32 Memory Specifications531
Memory Configuration531
- Device/Label Memory531
File Size Unit in Memory532
Memory Operation532
Files533
- File Types and Storage Memory533
- File Operation Available534
- File Size536
Chapter 33 Functions537
Safety Operation Mode539
- Checking the Safety Operation Mode539
- Switching the Safety Operation Mode540
- Operations Restricted in SAFETY MODE542
Continuous RUN Prevention in TEST MODE543
- Measuring the Continuous RUN Time in TEST MODE543
- Setting Method543
- Checking the Continuous RUN Time in TEST MODE543
Safety Diagnostic Function544
Safety Data Identify Check545
Safety Communication Function545
Device/Label Memory Area Setting546
- Default Capacity546
- Setting Range of Capacity of each Area547
- Setting Method549
Data Logging Function551
- Data to be Collected551
- Data Collection Conditions551
- Trigger Conditions551
- Output Settings551
- Auto Logging551
RAS Functions552
- Self-Diagnostic Function552
- Error Clear553
Chapter 34 Safety Devices, Safety Labels, and Constants556
Safety Devices556
- List of Safety Devices556
- Safety User Devices557
- Safety System Devices559
Safety Global Devices560
Safety Local Devices560
Safety Label561
- Safety Label Types561
- Classes563
- Data Types564
- Structures564
Constants564
Chapter 35 Basic Concept566
System567
System Switching between the Control System and Standby System567
System Consistency Check567
Operation Mode of the SIL2 Process CPU568
Operation Modes of the System568
Safety Operation Mode568
- Checking the Safety Operation Mode568
- Operations Restricted in SAFETY MODE569
Scan Configuration570
Determination of Control System/Standby System571
- When Starting up both Systems Simultaneously571
- When Starting up One System First572
- When One System Is Started Automatically Even Though a Tracking Communication Error Has Occurred574
- When Starting up the Previous Control System as the Control System579
35.9 State Transition of a System Using the SIL2 Process CPU580
Running a Safety Program581
- Overview581
- Safety Program582
- Safety Cycle Time584
- SIL2 Process CPU Operating Status585
Memory Specifications586
- Memory Configuration586
- File Size Unit in Memory587
- Memory Operation587
- Files588
  - Process Cpu592
Chapter 36 Procedure for Starting up a System Using the Sil2592
Overview592
Wiring599
- Wiring the Redundant Function Modules599
- Wiring to the Power Supply Modules in a System Using the SIL2 Process CPU600
Creating a Project601
Connecting a Personal Computer and a CPU Module602
System A/B Settings603
Writing Data to the Programmable Controller605
Monitoring the Program606
Chapter 37 Functions607
System Switching611
- System Switching Method611
- Operation at System Switching616
- Execution Availability of System Switching618
- Check Method of System Switching Information619
- Precautions621
Tracking Transfer624
- Tracking Data625
- Tracking Block and Tracking Trigger628
- Setting Procedure for Tracking Transfer629
- Tracking Transfer Setting630
- Safety Tracking Transfer Setting633
- Tracking Mode634
- Precautions637
Memory Copy from Control System to Standby System639
- Memory Copy with the Engineering Tool642
- Precautions643
System Consistency Check644
- File646
- Operating Status647
- Mounting Status of Main Base Unit647
- SD Memory Card648
- Safety Operation Mode648
Program Execution in both Systems649
- Operation of a Program Executed in both Systems650
- Precautions652
Redundant System Operation Setting654
- Standby System Output Setting655
Redundant Function Module Communication Test656
- Execution Procedure of the Module Communication Test656
Switching Safety Operation Mode657
Safety Diagnostic Function660
Safety Data Identify Check660
Safety Communication Function661
- Safety I/O Hold Time662
Online Change664
Constant Scan664
Remote Operation665
- Remote Run/Remote Stop/Remote PAUSE665
- Remote RESET666
- Precautions666
Device/Label Memory Area Setting667
- Default Capacity667
- Setting Range of Capacity of each Area667
- Setting Method669
RAS Functions671
- Self-Diagnostic Function671
- Error Clear673
- Clearing Errors on the Standby System CPU Module from the Control System CPU Module675
SLMP Communications676
Chapter 38 Safety Devices, Safety Labels, and Constants677
Safety Devices677
- List of Safety Devices677
- Safety User Devices678
- Safety System Devices681
Safety Global Devices682
Safety Local Devices682
Safety Label683
- Safety Label Types683
- Classes685
- Data Types686
- Structures686
Constants686
Chapter 39 Precautions on Programming687
39.1 Instructions Not Available in System Using SIL2 Process CPU687
- Instructions that Need to be Executed Again in a New Control System687
- Instructions Whose Operations Vary Depending on Tracking of the Signal Flow Memory690
- Instructions that Affect the Status of Another Instruction When Executed692
- Instructions that Cause Different Operation Results between the Control System and Standby System692
- Precautions for Using the COM or ZCOM Instruction693
- Precautions for Using the ADRSET Instruction693
Interrupt from Modules694
Precautions for Using the Annunciator (F)694
Precautions on Timers and Timer Function Blocks695
Precautions on Access to Intelligent Function Module or External Devices696
Precautions on Writing Data from GOT or External Devices698
Precautions on Outputting in the Middle of the Scan698
- Process Cpu699
Chapter 40 Maintenance and Inspection for a System Using Sil2 Process Cpu699
- Replacing a CPU Module and SIL2 Function Module700
- Replacing a Power Supply Module700
- Replacing a Redundant Power Supply Module701
- Replacing a Redundant Function Module701
- Replacing a Network Module701
- Replacing a Main Base Unit702
40.1 Module Replacement in a System Using the SIL2 Process CPU699
Appendices703
Appendix 1 Error Codes703
- Error Code System703
- Operation When an Error Occurs705
- Safety Output Operation When Error Occurs705
- How to Clear Errors705
- List of Error Codes705
Appendix 2 Event List790
- How to Read the Event List790
- Event List792
Appendix 3 Troubleshooting by Symptom800
- When the POWER LED of the Power Supply Module Turns off800
- When the READY LED of the CPU Module Turns off800
- When an Error Has Occurred in a Redundant Function Module801
- When an Error Has Occurred in a SIL2 Function Module801
- When an Error Has Occurred in a Safety Function Module802
- When the Specific Extension Base Unit Cannot be Recognized802
- When the Specific Q Series Extension Base Unit Cannot be Recognized802
- When Data Cannot be Written to the Programmable Controller803
- When Data Cannot be Read from the Programmable Controller803
- When the Operating Status of the CPU Module Cannot be Changed803
- When the Ethernet Function Cannot be Used803
- When the CC-Link IE Field Network Basic Function Cannot be Used803
- When the CPU Module Database Access Function Cannot be Used804
Appendix 4 List of Special Relay Areas805
- Diagnostic Information806
- System Information808
- SFC Information810
- System Clock812
- Fixed Scan Function Information815
- Drive Information816
- Instruction Related818
- Latch Area821
- Data Logging Function822
- CPU Module Data Backup/Restoration Function825
- File Transfer Function (FTP Client)826
- Memory Dump Function827
- Ethernet Function828
- Online Module Change Function829
- Redundant Function831
- Safety Information834
Appendix 5 List of Special Register Areas835
- Diagnostic Information836
- System Information848
- SFC Information852
- Drive Information855
- Instruction Related858
- Firmware Update Function860
- Latch Area862
- Data Logging Function864
- CPU Module Data Backup/Restoration Function866
- Interrupt Pointer Mask Pattern870
- Memory Dump Function871
- CPU Module Database Access Function872
- Ethernet Function873
- CC-Link IE Field Network Basic Function875
- Online Module Change Function876
- System Information (Process CPU)877
- Safety Information882
Appendix 6 List of Safety Special Relay Areas884
- System Clock885
Appendix 7 List of Safety Special Register Areas887
- System Information888
Appendix 8 Buffer Memory893
- Details on Buffer Memory Addresses896
Appendix 9 Processing Time900
- END Processing Time903
- Data Logging Function Processing Time915
- Memory Dump Function Processing Time923
- Database Function Processing Time924
- Process Control Function Processing Time925
- SFC Program Processing Time926
- SFC Program Switching927
- Redundant Function Processing Time928
Appendix 10Parameter List936
- CPU Parameters937
- Module Parameters938
Appendix 11 Target List and Operation Details of the Device/Label Access Service Processing Setting939
- Operation Details940
Appendix 12Program Restoration Information Write Selection944
- Precautions946
Appendix 13How to Use CPU Module Logging Configuration Tool947
- Specifications950
- Data Logging Procedure962
- Menu Items and Setting Methods963
Appendix 14List of Available SQL Commands for CPU Module Database Access Function998
- Data Operation1000
- Clause1002
- Aggregate Function1004
- Arithmetic Function1005
Appendix 15Added and Enhanced Functions1010
- Index1015
- Revisions1019
- Warranty1021
- Trademarks1026

Mitsubishi Electric MELSEC iQ-R-R04CPU - Page 524

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