7 ONLINE MODULE CHANGE
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7 ONLINE MODULE CHANGE
When changing a module online, carefully read the QCPU User's Manual (Hardware
Design, Maintenance and Inspection),section 12.4.1 "Online module change".
This chapter describes the specifications of an online module change.
(1) Perform an online module change by operating GX Developer.
(2) To ensure ease of offset/gain re-setting, there is a user range save/restoration function that is performed by executing the dedicated instruction or read/write from/to buffer memory.
POINT
(1) Perform an online module change after making sure that the system outside the programmable controller will not malfunction.
(2) To prevent an electric shock and malfunction of operating modules, provide means such as switches for powering off each of the external power supply and external devices connected to the module to be replaced online.
(3) After the module has failed, data may not be saved properly. Referring to
Section 3.4.15, therefore, prerecord the data to be saved (offset/gain values of the industrial shipment settings and user range settings in the buffer memory).
(4) It is recommended to perform an online module change in the actual system in advance to ensure that it would not affect the other modules by checking the following:
• Means of cutting off the connection to external devices and its configuration are correct.
• Switching ON/OFF does not bring any undesirable effect.
(5) Do not install/remove the module to/from the base unit, or the terminal block to/from the module more than 50 times after the first use of the product. (IEC
61131-2 compliant)
Failure to do so may cause malfunction.
(Note)
The dedicated instruction cannot be executed during an online module change. When using the dedicated instruction to execute save/restoration, therefore, execute save/restoration in the other system .
If the other system is unavailable, execute restoration by performing write to the buffer memory.
: If the module is mounted on the remote I/O station, execute save/restoration in the other system mounted on the main base unit. (Save/restoration cannot be executed in the other system mounted on the remote I/O station.)
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7.1 Online Module Change Conditions
The CPU, MELSECNET/H remote I/O module, A/D converter module, GX Developer and base unit given below are needed to perform an online module change.
(1) CPU
The Process CPU is required.
For precautions for multiple CPU system configuration, refer to the QCPU User's
Manual (Multiple CPU System).
(2) MELSECNET/H remote I/O module
The module of function version D or later is necessary.
(3) A/D converter module
The module of function version C or later is necessary.
(4) GX Developer
GX Developer of Version 7.10L or later is necessary.
GX Developer of Version 8.18U or later is required to perform an online module change on the remote I/O station.
(5) Base unit
1) When the slim type main base unit (Q3 SB) is used, an online module change cannot be performed.
2) When the power supply module unnecessary type extension base unit
(Q5 B) is used, online module change cannot be performed for the modules on all the base units connected.
7
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7.2 Online Module Change Operations
The following gives the operations performed for an online module change.
X/Y refresh
CPU operation : Executed : Not executed
GX Configurator
FROM/TO instruction
1
Dedicated instruction
Device test
Initial setting parameter
Monitor/ test
(User operation)
(Intelligent function module operation)
(1) Conversion disable
Turn OFF all Y signals that were turned ON by a sequence program.
Module is operating as usual.
(2) Dismounting of module
Operate GX Developer to start an online module change.
Module stops operating.
RUN LED turns off.
Conversion disabled.
Click the [Execution] button of GX Developer to make the module dismountable.
Dismount the corresponding module.
(3) Mounting of new module
Mount a new module.
After mounting the module, click the [Execution] button of GX Developer.
X/Y refresh resumes and the module starts.
RUN LED turns on.
Default operation
(X0 remains OFF)
When there are initial setting parameters, operation is performed according to the initial setting parameters at this point.
Operation check before control start
(4) Operation check
Click the [Cancel] button of
GX Developer to leave the online mode.
Conduct an operation test on the new module using
"Device test" of GX Developer or "Monitor/test" of
GX Configurator.
Perform user range restoration processing by write to buffer memory at this point.
Module operates according to test operation
2
Operation check completed
(5) Resumption of control
Operate GX Developer to resume the online module change mode, and click the
[Execution] button to resume control.
X0 (Module Ready) turns ON.
Start is made when X0 turns from OFF to ON.
Operation is performed according to the initial setting sequence.
2
1: Access to the intelligent function module device (U \G ) is included.
2: In the absence of the operation marked 2, the operation of the intelligent function module is the operation performed prior to that.
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7.3 Online Module Change Procedure
There are the following online module change procedures depending on whether the user range setting has been made or not, whether the initial setting of GX Configurator-
AD has been made or not, and whether the other system exists or not.
Range setting Initial setting Other system Reference section
Industrial shipment setting GX Configurator-AD
Industrial shipment setting Sequence program
User range setting
User range setting
GX Configurator-AD
GX Configurator-AD
User range setting
User range setting
—
Present
Section 7.3.2
Section 7.3.3
Sequence program Present Section
Sequence program Absent Section
7.3.1 When industrial shipment setting is used and initial setting was made with GX
Configurator-AD
(1) Conversion disable
(a) Set the A/D conversion enable/disable setting (buffer memory address 0:
Un\G0) for all channel conversion disable and turn Operation Condition
Setting Request (Y9) from OFF to ON to stop conversion.
After confirming that conversion has stopped with the A/D conversion completed flag (buffer memory address 10: Un\G10), turn off Operation
Condition Setting Request (Y9).
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(2) Dismounting of module
(a) After choosing [Diagnosis] - [Online module change] on GX Developer to enter the "Online module change" mode, double-click the module to be changed online to display the "Online module change" screen.
(b) Click the "Execution" button to enable a module change.
If the following error screen appears, click the [OK] button, dismount the module as-is, and mount a new module.
(c) After confirming that the "RUN" LED of the module has turned off, remove the terminal block and dismount the module.
POINT
Always dismount the module. If mounting confirmation is made without the module being dismounted, the module will not start properly and the "RUN" LED will not be lit.
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(3) Mounting of new module
(a) Mount a new module to the same slot and install the terminal block.
(b) After mounting the module, click the [Execution] button and make sure that the "RUN" LED is lit. Module Ready (X0) remains OFF.
(a) To make an operation check, click the [Cancel] button to cancel control resumption.
(b) Click the [OK] button to leave the "Online module change" mode.
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(c) Click the [Close] button to close the System monitor screen.
(d) Monitor the digital output values (buffer memory addresses 11 to 18:
Un\G11 to 18) to check that proper conversion has been made.
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(5) Resumption of control
(a) After choosing [Diagnosis] - [Online module change] on GX Developer to redisplay the "Online module change" screen, click the [Execution] button to resume control. The FROM/TO instruction for the module resumes.
(b) The "Online module change completed" screen appears.
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7.3.2 When industrial shipment setting is used and initial setting was made with sequence program
(a) Set the A/D conversion enable/disable setting (buffer memory address 0:
Un\G0) for all channel conversion disable and turn Operation Condition
Setting Request (Y9) from OFF to ON to stop conversion.
After confirming that conversion has stopped with the A/D conversion completed flag (buffer memory address 10: Un\G10), turn off Operation
Condition Setting Request (Y9).
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(2) Dismounting of module
(a) After choosing [Diagnosis] - [Online module change] on GX Developer to enter the "Online module change" mode, double-click the module to be changed online to display the "Online module change" screen.
(b) Click the "Execution" button to enable a module change.
If the following error screen appears, click the [OK] button, dismount the module as-is, and mount a new module.
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(c) After confirming that the "RUN" LED of the module has turned off, remove the terminal block and dismount the module.
POINT
Always dismount the module. If mounting confirmation is made without the module being dismounted, the module will not start properly and the "RUN" LED will not be lit.
(3) Mounting of new module
(a) Mount a new module to the same slot and install the terminal block.
(b) After mounting the module, click the [Execution] button and make sure that the "RUN" LED is lit. Module Ready (X0) remains OFF.
(a) To make an operation check, click the [Cancel] button to cancel control resumption.
(b) Click the [OK] button to leave the "Online module change" mode.
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(c) Click the [Close] button to close the System monitor screen.
(d) Referring to (1), enable the conversion of the channels to be used, and monitor the digital output values (buffer memory addresses 11 to 18:
Un\G11 to 18) to check that proper conversion has been made.
(e) Since the new module is in a default status, it must be initialized by a sequence program after control resumption.
Before performing initialization, check whether the contents of the initialization program are correct or not.
1) Normal system configuration
The sequence program should perform initialization on the leading edge of Module READY (X9) of the A/D converter module.
When control resumption is executed, Module READY (X0) turns ON and initialization is performed. (If the sequence program performs initialization only one scan after RUN, initialization is not performed.)
2) When used on remote I/O network
Insert a user device that will execute initialization at any timing
(initialization request signal) into the sequence program. After control resumption, turn ON the initialization request signal to perform initialization. (If the sequence program performs initialization only one scan after a data link start of the remote I/O network, initialization is not performed.)
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(5) Resumption of control
(a) After choosing [Diagnosis] - [Online module change] on GX Developer to redisplay the "Online module change" screen, click the [Execution] button to resume control. The FROM/TO instruction for the module resumes.
(b) The "Online module change completed" screen appears.
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7.3.3 When user range setting is used and initial setting was made with GX Configurator-AD
(other system is available)
(a) Set the A/D conversion enable/disable setting (buffer memory address 0:
Un\G0) for all channel conversion disable and turn Operation Condition
Setting Request (Y9) from OFF to ON to stop conversion.
After confirming that conversion has stopped with the A/D conversion completed flag (buffer memory address 10: Un\G10), turn off Operation
Condition Setting Request (Y9).
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(2) Dismounting of module
(a) After choosing [Diagnosis] - [Online module change] on GX Developer to enter the "Online module change" mode, double-click the module to be changed online to display the "Online module change" screen.
(b) Click the "Execution" button to enable a module change.
If the following error screen appears, the user range cannot be saved.
Click the [OK] button, and perform the operation in Section 7.3.4 (2)(c) and later.
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(c) After confirming that the "RUN" LED of the module has turned off, remove the terminal block and dismount the module.
POINT
Always dismount the module. If mounting confirmation is made without the module being dismounted, the module will not start properly and the "RUN" LED will not be lit.
(3) Mounting of new module
(a) Mount the dismounted module and new module to the other system.
(b) Using the G(P).OGLOAD instruction, save the user set values to the CPU device. Refer to Appendix 2.2 for the G(P).OGLOAD instruction.
(c) Using the G(P).OGSTOR instruction, restore the user set values to the module. Refer to Appendix 2.3 for the G(P).OGSTOR instruction.
(d) Dismount the new module from the other system, mount it to the slot from where the old module was dismounted in the original system, and install the terminal block.
(e) After mounting the module, click the [Execution] button and make sure that the "RUN" LED is lit. Module Ready (X0) remains OFF.
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(a) To make an operation check, click the [Cancel] button to cancel control resumption.
(b) Click the [OK] button to leave the "Online module change" mode.
(c) Click the [Close] button to close the System monitor screen.
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(d) Monitor the digital output values (buffer memory addresses 11 to 18:
Un\G11 to 18) to check that proper conversion has been made.
(5) Resumption of control
(a) After choosing [Diagnosis] - [Online module change] on GX Developer to redisplay the "Online module change" screen, click the [Execution] button to resume control. The FROM/TO instruction for the module resumes.
(b) The "Online module change completed" screen appears.
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7.3.4 When user range setting is used and initial setting was made with GX Configurator-AD
(other system is unavailable)
(a) On the Operating condition setting screen of GX Configurator-AD, set
"Disable" in the Setting value field of CH A/D conversion enable/disable setting, and click the [Execute test] button.
Monitor the A/D conversion completed flag (buffer memory address 10:
Un\G10) and confirm that conversion has stopped.
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(b) After making sure that the indication in the Current value field of CH A/D conversion enable/disable setting is "Disable", change the Setting value field of Operating condition setting request to "Setting request", and click the [Execute test] button to stop conversion.
(c) If the saved buffer memory contents are not yet prerecorded, record them in the following procedure.
1) Display the pass data screen of GX Configurator-AD.
2) Set the pass data classification setting and make a pass data read request. (Refer to Section 5.6.4, 5.6.5.)
3) Compare the current values of the industrial shipment settings and user range settings offset/gain values with those of the range reference table. Refer to Section 7.4 for the range reference table.
4) If the values are proper, record the offset/gain values of the pass data classification setting, industrial shipment settings and user range settings.
: The Q68ADV/Q68ADI does not require the setting and recording of the pass data classification setting.
POINT
If the buffer memory values compared with the reference table are not proper, save and restoration of the user range cannot be executed.
Before executing module control resumption, make offset/gain setting in the GX
Configurator-AD. (see Section 5.6.2)
Note that if module control is resumed without offset/gain setting being made, operation will be performed with the default values.
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(2) Dismounting of module
(a) After choosing [Diagnosis] - [Online module change] on GX Developer to enter the "Online module change" mode, double-click the module to be changed online to display the "Online module change" screen.
(b) Click the "Execution" button to enable a module change.
If the following error screen appears, the user range cannot be saved.
Click the [OK] button, and perform the operation in Section (2)(c) and later.
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(c) After confirming that the "RUN" LED of the module has turned off, remove the terminal block and dismount the module.
POINT
Always dismount the module. If mounting confirmation is made without the module being dismounted, the module will not start properly and the "RUN" LED will not be lit.
(3) Mounting of new module
(a) Mount a new module to the same slot and install the terminal block.
(b) After mounting the module, click the [Execution] button and make sure that the "RUN" LED is lit. Module Ready (X0) remains OFF.
(a) To make an operation check, click the [Cancel] button to cancel control resumption.
(b) Click the [OK] button to leave the "Online module change" mode.
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(c) Click the [Close] button to close the System monitor screen.
(d) On the pass data screen of GX Configurator-AD, set the prerecorded values and make a pass data write request. (Refer to Section 5.6.4, 5.6.5)
(e) Monitor the digital output values (buffer memory addresses 11 to 18:
Un\G11 to 18) to check that proper conversion has been made.
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(5) Resumption of control
(a) After choosing [Diagnosis] - [Online module change] on GX Developer to redisplay the "Online module change" screen, click the [Execution] button to resume control. The FROM/TO instruction for the module resumes.
(b) The "Online module change completed" screen appears.
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7.3.5 When user range setting is used and initial setting was made with sequence program
(other system is available)
(a) Set the A/D conversion enable/disable setting (buffer memory address 0:
Un\G0) for all channel conversion disable and turn Operation Condition
Setting Request (Y9) from OFF to ON to stop conversion.
After confirming that conversion has stopped with the A/D conversion completed flag (buffer memory address 10: Un\G10), turn off Operation
Condition Setting Request (Y9).
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(2) Dismounting of module
(a) After choosing [Diagnosis] - [Online module change] on GX Developer to enter the "Online module change" mode, double-click the module to be changed online to display the "Online module change" screen.
(b) Click the "Execution" button to enable a module change.
If the following error screen appears, the user range cannot be saved.
Click the [OK] button, and perform the operation in Section 7.3.6 (2)(c) and later.
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(c) After confirming that the "RUN" LED of the module has turned off, remove the terminal block and dismount the module.
POINT
Always dismount the module. If mounting confirmation is made without the module being dismounted, the module will not start properly and the "RUN" LED will not be lit.
(3) Mounting of new module
(a) Mount the dismounted module and new module to the other system.
(b) Using the G(P).OGLOAD instruction, save the user set values to the CPU device. Refer to Appendix 2.2 for the G(P).OGLOAD instruction.
(c) Using the G(P).OGSTOR instruction, restore the user set values to the module. Refer to Appendix 2.3 for the G(P).OGSTOR instruction.
(d) Dismount the new module from the other system, mount it to the slot from where the old module was dismounted in the original system, and install the terminal block.
(e) After mounting the module, click the [Execution] button and make sure that the "RUN" LED is lit. Module Ready (X0) remains OFF.
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(a) To make an operation check, click the [Cancel] button to cancel control resumption.
(b) Click the [OK] button to leave the "Online module change" mode.
(c) Click the [Close] button to close the System monitor screen.
(d) Referring to (1), enable the conversion of the channels to be used, and monitor the digital output values (buffer memory addresses 11 to 18:
Un\G11 to 18) to check that proper conversion has been made.
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(e) Since the new module is in a default status, it must be initialized by a sequence program after control resumption.
Before performing initialization, check whether the contents of the initialization program are correct or not.
1) Normal system configuration
The sequence program should perform initialization on the leading edge of Module READY (X9) of the A/D converter module.
When control resumption is executed, Module READY (X0) turns ON and initialization is performed. (If the sequence program performs initialization only one scan after RUN, initialization is not performed.)
2) When used on remote I/O network
Insert a user device that will execute initialization at any timing
(initialization request signal) into the sequence program. After control resumption, turn ON the initialization request signal to perform initialization. (If the sequence program performs initialization only one scan after a data link start of the remote I/O network, initialization is not performed.)
(5) Resumption of control
(a) After choosing [Diagnosis] - [Online module change] on GX Developer to redisplay the "Online module change" screen, click the [Execution] button to resume control. The FROM/TO instruction for the module resumes.
(b) The "Online module change completed" screen appears.
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7.3.6 When user range setting is used and initial setting was made with sequence program
(other system is unavailable)
(a) Set the A/D conversion enable/disable setting (buffer memory address 0:
Un\G0) for all channel conversion disable and turn Operation Condition
Setting Request (Y9) from OFF to ON to stop conversion.
After confirming that conversion has stopped with the A/D conversion completed flag (buffer memory address 10: Un\G10), turn off Operation
Condition Setting Request (Y9).
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(b) If the saved buffer memory contents are not yet prerecorded, record them in the following procedure.
1) Make the pass data classification setting (buffer memory address
200: Un\G200).
2) Turn Operation Condition Setting Request (Y9) from OFF to ON.
3) Compare the offset/gain values of the industrial shipment settings and user range settings (buffer memory addresses 202 to 233: Un\G202 to
Un\G233) with the range reference table. Refer to Section 7.4 for the range reference table.
4) If the values are proper, record the offset/gain values of the pass data classification setting , industrial shipment settings and user range settings.
: The Q68ADV/Q68ADI does not require the setting and recording of the pass data classification setting.
POINT
If the buffer memory values compared with the reference table are not proper, save and restoration of the user range cannot be executed.
Before executing module control resumption, follow the flowchart in Section 4.6 and make offset/gain setting in the device test of GX Developer.
Perform mode switching by making the setting of the mode switching setting (buffer memory addresses 158, 159: Un\G158, Un\G159) and turning Operation Condition
Setting Request (Y9) from OFF to ON.
Note that if module control is resumed without offset/gain setting being made, operation will be performed with the default values.
(2) Dismounting of module
(a) After choosing [Diagnosis] - [Online module change] on GX Developer to enter the "Online module change" mode, double-click the module to be changed online to display the "Online module change" screen.
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(b) Click the "Execution" button to enable a module change.
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If the following error screen appears, the user range cannot be saved.
Click the [OK] button, and perform the operation in Section (2)(c) and later.
(c) After confirming that the "RUN" LED of the module has turned off, remove the terminal block and dismount the module.
POINT
Always dismount the module. If mounting confirmation is made without the module being dismounted, the module will not start properly and the "RUN" LED will not be lit.
(3) Mounting of new module
(a) Mount a new module to the same slot and install the terminal block.
(b) After mounting the module, click the [Execution] button and make sure that the "RUN" LED is lit. Module Ready (X0) remains OFF.
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(a) To make an operation check, click the [Cancel] button to cancel control resumption.
(b) Click the [OK] button to leave the "Online module change" mode.
(c) Click the [Close] button to close the System monitor screen.
(d) Choose [Online] - [Debug] - [Device test] on GX Developer and set the prerecorded values to the buffer memory.
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(e) Turn the user range write request (YA) from OFF to ON to restore the user set values to the module.
After confirming that the offset/gain setting mode status flag (XA) is
ON, turn OFF the user range write request (YA).
(f) Referring to (1), enable the conversion of the channel to be used, and monitor the digital output values (buffer memory addresses 11 to 18:
Un\G11 to 18) to check that proper conversion has been made.
(g) Since the new module is in a default status, it must be initialized by a sequence program after control resumption.
Before performing initialization, check whether the contents of the initialization program are correct or not.
1) Normal system configuration
The sequence program should perform initialization on the leading edge of Module READY (X9) of the A/D converter module.
When control resumption is executed, Module READY (X0) turns ON and initialization is performed. (If the sequence program performs initialization only one scan after RUN, initialization is not performed.)
2) When used on remote I/O network
Insert a user device that will execute initialization at any timing
(initialization request signal) into the sequence program. After control resumption, turn ON the initialization request signal to perform initialization. (If the sequence program performs initialization only one scan after a data link start of the remote I/O network, initialization is not performed.)
(5) Resumption of control
(a) After choosing [Diagnosis] - [Online module change] on GX Developer to redisplay the "Online module change" screen, click the [Execution] button to resume control. The FROM/TO instruction for the module resumes.
(b) The "Online module change completed" screen appears.
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7.4 Range Reference Table
The range reference tables are given below.
(1) Reference table for offset/gain values of industrial shipment settings (buffer memory addresses 202 to 233: Un\G202 to 233)
Address (Decimal)
CH1 CH2 CH3 CH4
The reference values change depending on the setting of the pass data classification setting (buffer memory address 200: Un\G200).
Description
Pass data classification setting
Voltage specified
Current specified
Voltage specified
Current specified
Reference value
(Hexadecimal)
Approx. 800C
H
Approx. 800C
H
Approx. FA64
H
Approx. BD38
H
Address (Decimal)
CH1 CH2 CH3 CH4 CH5 CH6 CH7 CH8
Description
Reference value
(Hexadecimal) value Approx.
H gain FA64
H
Address (Decimal)
CH1 CH2 CH3 CH4 CH5 CH6 CH7 CH8
Description
Reference value
(Hexadecimal) value Approx.
H gain BD38
H
(2) Reference table for user range settings offset/gain values (buffer memory addresses 218 to 233: Un\G218 to 233)
Example: When the offset value and gain value of channel 1 are 1V and 5V, respectively, in the Q68ADV, the reference value of the CH1 user range settings offset value (buffer memory address 218: Un\G218) is approx. 8C46
H
and that of the CH1 user range settings gain value
(buffer memory address 220: Un\G220) is approx. BD64
H
.
Offset/gain value Reference value (Hexadecimal)
Voltage
Current
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7.5 Precautions for Online Module Change
The following are the precautions for online module change.
(1) Always perform an online module change in the correct procedure. A failure to do so can cause a malfunction or failure.
(2) If an online module change is made with the user range setting, the accuracy after that will fall to about less than three times of the accuracy before that.
Re-set the offset/gain values as necessary.
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