{ELSEC-iQ-R_Series_Basics_naO0166_eng Fw Changes for the Better PLC MELSEC iQ-R Series Basic This course is for participants who will use the MELSEC iQ-R Series programmable controller for the first time. Copyright ©2014 Mitsubishi Electric Corporation. All Rights Reserved, Lva}o0166ENGWW 1-MELSEC-iQ-R_Series_Basics_na00166_eng el —ia Cz Purpose of the course aoe ‘This course explains the basic structure and configuration method of programmable controllers for those who will use the MELSEC iQ-R Series programmable controllers (MELSEC iQ-R Series) for the first time. Programmable controller system is generally configured in the following procedure: Decide where to apply the automation system Prepare the required equipment Installation and wiring Create various programs that execute the automated procedures The following course is a prerequisite prior to taking this course: 1. FA Equipment for Beginners (PLCs)WW 1-MELSEC-iQ-R_Series_Basics_na00166_eng Introdu ul Course structure ‘The contents of this course are as follows. Itis recommended that you start from Chapter 1. Chapter 1 - Designing the programmable controller system, Learn about the MELSEC iQ-R Series, programmable controller system example, and module selection Chapter 2 - Installation and wiring Lear about module installation, 1/0 number assignment, and wiring Chapter 3 - Creating and executing programs Learn about connecting the CPU module to a personal computer, and programming Final Test Pass grade: 60% or higher is requiredWW 1-MELSEC-iQ-R_Series_Basics_na00166_eng Ua How to use this ‘Learning tool eae) Go to the next page Cee Rao Back to the previous page, Terese Td “Table of Contents" will be displayed, enabling you to navigate to| the desired page. ee a} Exit the leaming.WW 1-MELSEC-iQ-R_Series_Basics_na00166_eng ehh Cautions for use Safety precautions When you leam based on using actual products, please carefully read the safety precautions in the corresponding manuals. Precautions in this course The displayed screens of the software version that you use may differ from those in this course. This course is for the following software version: ~ GX Works3 Version 1.0018WW 1-MELSEC-iQ-R_Series_Basics_na00166_eng Designing the programmable controller system This chapter explains the programmable controller system configuration and module selection based on the MELSEC iQ-R Series. ‘LI MELSEC iQ Series concept 1.2 MELSEC iQ-R Series system configuration 113 Programmable controller system example 114 Modules for the example sorting system 15 Module selection 16 SummaryWW 1-MELSEC-iQ-R_Series_Basics_na00166_eng cB j MELSEC iQ-R Series concept Mitsubishi programmable controllers, which are also referred to as programmable automation controllers (PAC), realize automation in various control situations or applications. ‘The MELSEC iQ-R Series models, which were released in 2014, are @ new revolutionary, next generation controller series building a new era in automation for medium to large-scale control systems. Designed from the ground up, the control system is based on common problems faced by customers. Productivity Improve productivity ‘through advanced ee a performance/ LCL Seamless network functionality z fetes sytem Engineering ern ore Reducing development Security sens Herel: Robust security that | engineering Jeanbe reed on Maintenance Reduce maintenance costs and downtime PN icing easier ‘maintenance features Quality i orensve compatibility with b)exsting, products Reliable and trusted IMELSEC product qualityWW 1-MELSEC-iQ-R_Series_Basics_na00166_eng el ica € 12 | MELSEC iQ-R Series system configuration , eos This section explains about the basic MELSEC iQ-R Series system configuration The CPU module, main base unit, and power supply module are the three essential modules required to configure a control system Multi-CPU system mextension base unit ‘extends the contol system t2 up to seven levelsWG L-MELSEC-iQ-R_Series | jes_na00166_eng Programmable controller system example This section explains about the sarting process. atl. Nu “i crates that have passed Paes Sorting | I Sorting process HHH open HI) yy) H}}) Please dick J to proceed tothe next page. HAMA To view saan, click on the “Replay” button,Series_Basics_na00166_eng Modules for the example sorting system In this example sorting system, various modules are used as shown below: ‘CPU module Input module Executes the control program based on Receives digital signals from a sensor, light nput signals, which are then and relays that information to the CPU. processed as digital output signals via rik ‘the eutput modules ‘Output module Receives Instructions from the (CPU module, and relays digital ‘output signals to the soring ‘guide-ra's Power supply module Sorting Sorting uide-als uide allsWW 1-MELSEC~iQ-R_Series_Basics_na00166_eng Module selection The MELSEC iQ-R Series consists of a wide-range of modules that can be used for various automation applications. In the example sorting system, a digital /O (nput and Output) module is used as the main interface to external digital signals, Motion vanaloa VO: control MELSEC iQ-R Series Jog 7Wl L-MELSEC-iQ-R_Series_Basics_na00166_eng oh iets € a I/O module selection ) Goo The following points must be considered when selecting 2 suitable /O module: + How many I/O devices are required (Number of /O points) + Input/output voltage The example sorting system consists of: + One input device (proximity sensor) + Two output devices (sorting guide-rails) + InputVoutput voltage of 24 V DC By considering the points above, the following 1/0 modules are selected ib Po ae Module name Rated input voltage Number of input points RxAQCT 2avoc 16 points RX40C7 RYAONTSP_ Ce ae uailcdaec hale saa uaeekekecnitaa RYAONTSP. 12to24V DC 16 points Sink type and source type output modules are available depending on the wiring system used. With this example, the sink type output module was selected. (The difference between the source type and sink type is explained in Chapter 2)Wl L-MELSEC-iQ-R_Series_Basics_na00166_eng ee € TE CPU modu selection ) sao ‘The following points must be considered when selecting a suitable CPU module: + Total number of /O points required + Program memory capacity Programs are stored in the CPU module, therefore an adequate CPU module allowing for the progrem size should be considered. Generally a large program capacity is required for large-scale applications. In order to allow for any future additions to the control system, please select a module with a program capacity considering the extra memory requirements, For this example, the following CPU module was selected: Prd ipa Program capacity 4096 pots ak steps ROACPUWW 1-MELSEC-iQ-R_Series_Basics_na00166_eng ‘The base unit is the main backplane to the system and holds the modules together as well as providing data communications via the system bus, The number of installable modules varies according to the capacity or slot-size of the base unit. Currently three different sizes are available, 5-, 8, 12-slot type, Once the control system size and required modules are decided, a suitable base unit allowing for the module I/O slot capacity is selected. In order to allow for any future additions, please select a base unit size considering the extra requirements For this example, the following base unit was selected: ea eres a aWW 1-MELSEC-iQ-R_Series_Basics_na00166_eng ez Power supply module sel n ) cao ‘When selecting a suitable power supply module, the required current consumption across the base unit has to be calculated as to provide an adequate power supply to the control system. ‘The concept of how power is consumed by each installed module on the base unit is shown below. ‘The capacity of the power supply module is dapletud, please consider the use of an extension base nit orto reduce the amount of curently installed modules. nd of animaton Please cick Jt proceed tothe rest page ‘To view again, click on the “Replay tautton Replay el —iaWl L-MELSEC-iQ-R_Series_Basics_na00166_eng module se! The consumption current can automatically be calculated using two different methods: + MELSEC iQ-R Series "Model Selection System” + Via the programming software "GX Works3" Power su; Confirming the power supply consumption using GX Works3 easelcabe Sot Model Name Congumoson Curent Tota Consumption Curent Total Org Votage Rose ase 0.504) Total 0 Ponts 0 Port / 3096 Pont] {Power Ssh) ave [ou] ROACPU ‘0.67A| Eo io) wae a 1 vais oun Total Consumption Current 1.5A / 6.5A\ Ce aen tee a Please note, the Model Selection System can be obtained from your local Mitsubishi Electric or sales representative.Wl L-MELSEC-iQ-R_Series_Basics_na00166_eng oh iets em Power supply module sel n ) cao For the example sorting system, the total current supply required by the combination of the base unit, CPU module, input module, and output module is 15 A. ‘Therefore, the following power supply was selected: cd SOON:WW 1-MELSEC-iQ-R_Series_Basics_na00166_eng el —ia —_ In this chapter, you have learned: + MELSEC iQ-R Series concept + MELSEC iQ-R Series system configuration + Modules for the example sorting system + Module selection Important points to consider Se ea Ree ens Deen Reed Reet Programmable controller system example ‘CPU module Main base unit Power supply module Number of VO devices Input/output volage Total number of YO points Program capacity Number of required modules Total current consumption of each mociule usedWl L-MELSEC-iQ-R_Series_Basics_na00166_eng Installation and wirin ‘This chapter explains about both the module installation and methods used for wiring, 2.1 Installation environment 2.2 Connecting the CPU module internal battery 2.3 Module installation 2.40 number assignment 25 Wiring 2.6 SummaryWl L-MELSEC-iQ-R_Series_Basics_na00166_eng Installation environment goo ‘The MELSEC iQ-R Series is a programmable automation controller designed for using in industrial environments. In general, control systems are installed within a specialized control cabinet, which prevents an accumulation of dust particles and provides some level of protection against outside electrical noise interference. The order of installation isto fix the base unit first inside the control cabinet, and then to install each module as required to tthe base unit, Installation in the following environments should be avoided: eB + High ambient temperature + High ambient humidity, condensation oo + posure to intermittent or + Aircontaining a high continuous vibrations, of concentration of dust large-torce impacts partides + Presence of inflammable ‘or corrosive gast For more details about supported installation environments, please refer to the general specifications in the relevant, installation manuals. *Some modules are available with 2 conformal coating according to IEC60721-3-3 Class 3C2. Please contact your local Mitsubishi Electric office or sales representative for further details.WW 1-MELSEC-iQ-R_Series_Basics_na00166_eng Se) Connecting the CPU module internal batte: coo ‘The CPU module allows an intemal battery to be connected as to ensure data retention in the event the main power supply is disconnected. When shipping, the internal battery is not connected as to conserve the battery power. Therefore, before using the CPU module, itis recommended that the internal battery is connected to the CPU module. Please refer to the animation below showing the relevant steps of installation’ L_ Open the batter compartment ‘cover located atthe bottom ofthe CPU module ¥ 2 Remove the cover and connect the battery connector to the socket located inside the cover Pease ck) 10 proceed othe 3 Reatlach the cover to the CPU next poge. housing and ciose the battery compartment cover To view again dick on the “Replay” buttonWW 1-MELSEC-iQ-R_Series_Basics_na00166_eng 5 | Module installation ‘The modules within the MELSEC iQ-R Series are installed onto the base unit as shown below. ‘L_ Algn the bottom of the module \with the recess located on the base & Press onta the base unit bus ‘connector until the top catch engages the module in place s ped ene 3. Tighten the module ing bolt to a rec Tighten the module fing bal Please click GJ to proceed tothe provide a sturdy installation on the rest page Base unit Toview again, click on the “Replay button,Wl L-MELSEC-iQ-R_Series_Basics_na00166_eng a) eal Modules and various slots ) cao Different types of slots are present on the base unit for the power supply module, CPU module, and I/O modules. CPU modules can also be installed onto the first 3 1/0 slots in a multiple CPU control system.[@ L-MELSEC-iQ-R_Series_Basics_na00166_eng eli ell Y/O number assignment ) Gao + When an 1/0 module (except a power supply and CPU module) is installed onto the base unit, an 1/O address number is automatically assigned. This address is used to identify YO signals wit and is allocated 16 points by default. The /O addressing usually starts from the left most module adjacent to the last CPU module on the right, + VO numbers are expressed in hexadecimal and start from 0. + "xis appended for an input module, and "Y" is appended for an output module. + After assignment, the correspondence between the I/O number and extemal device interface should be confirmed Input module Output module X0 to XF yi0to VIF (16pommts) 6 points) the 1/0 module from the CPU Correspondence between /O numbers and extemal devices (example sorting system) od Coa Proximity sensor, which x0 | turns ON upon Input | x0 tox detecting a crate module | as points) xd toxF |Notused 10 | sorting guide-ral that epee modula | as points) Vi2to VF |Notused[@ L-MELSEC-iQ-R_Series_Basics_na00166_eng eke Gaal w > ooo ‘After attaching the modules to the base unit, the power supply and external devices must be wired. Power supply module wiring 2 This section explains about wiring to the power supply module. + For wiring, the terminal cover in front of the module must be opened. * AC power is connected to the power supply terminals L and N, respectively. (The L and N terminals are clearly labeled) Take care not to connect the AC power cables to the ERR contact terminals. + Itis recommended that both the terminals FG and LG should be earthed accordingly. Color coding of AC mains wiring may vary according to the country used, tnd of animation Presse dick J to proceed to then page To view again cick on the “Replay” button 100-240V AC(@ 2-MELSEC~iQ-R_Series_Basics_na00166_eng eli en Input module wiring ) cao ‘An external power supply (24 V DC) is separately required in addition to the base unit power supply module. It has a single common terminal (COM), which can be wired as a positive (common positive rail is used) or negative (common negative ral is used) common. The different wiring types can be switched accordingly The animation illustrates the wiring of ‘the input module. The MELSEC iQ-R Series input modules can be set as positive or negative common. ogative commnon Pease cick the bution above to swich between posiveand negative conmnon wing Pleas cick (to proce othe non.[@ L-MELSEC-iQ-R_Series_Basics_na00166_eng Output module wirin, ‘There are two distinctive ways to wire the output module, depending on the external devices used. It has a single common terminal (COM), sink wiring when the negative rail is used, and source wiring when the positive rail is used as the common. Each wiring method requites a different type of module. The output module requires an external power supply, which should be connected to either the +V or OV terminals accordingly. Cckthe button above to such between snk and source wiring ‘Aor config each wring please cick.) to proceed tothe next[@ L-MELSEC-iQ-R_Series_Basics_na00166_eng eli ? In this chapter, you have learned: + Appropriate installation environment + How to connect the CPU module internal battery + Installation of various modules + 1/0 number assignment method + Various wiring methods Important points to consider: es areata battery Pen Teer ad Ce YO module wicing “The MELSEC iQ-R Series contol system requires to be installed in an environment as outlined in the general specifications Before being installed to a base unit the CPU module needs its battry connector to be plugged “The power must be turned OFF before instaling/removing a module Different types of slots are present on the hase unt forthe power supply madula, CPU! module, ‘and 1/0 modules (CPU Modules can also be installed onto the first 3 /0 slots in a multiple CPU, ‘control system) YO numbers are assigned to the modules installed in the base unit (except CPU and power ‘supply modules) VO numbers ate assigned in increments of 16 points and assigned from the left “The AC pawer supply is connected to the power input terminals Land Nand not connected to ‘the ERR contact Aways earth the poner supply module terminals FG and LG For I/O modules, an external power supply (24 VDC) is required in addition to the base unit power supply module ‘An 1/0 module equipped with common terminals (COM), which can be used 2s input or output ‘terminal, reduces wiring and space[@ L-MELSEC-iQ-R_Series_Basics_na00166_eng Creating and execu’ rograms ‘This chapter explains about creating and executing programs. 3.1 Programming outline 3.2 Connecting the CPU module to a personal computer 3.3 Creating programs 34 Registering and executing programs 3.5 Summary[@ L-MELSEC-iQ-R_Series_Basics_na00166_eng Programming outline ‘The MELSEC iQ-R Series programmable controller requires a program to exeaute control tasks within the system, ‘The program consists of a dedicated programming language such as Ladder, Structured Text (ST), and/or function block (F. The program is created using a personal computer installed with GX Works3, which is @ dedicated engineering software for the MELSEC iQ-R Series. Once the program is created itis then uploaded to the CPU module which in ‘turn is executed in the control CPU. Programs can be easily modified as to align with future changes in the control system configuration or control method For this course, the ladder programming language is used to explain basic programming practices. ia Executing the program within the CPU module TI End of animation Please cick Jt proceed othe rt page ‘Ta view again, lick on the "Replay* button, ReviayWW 1-MELSEC-iQ-R_Series_Basics_na00166_erg ——__ emi Connecting the CPU module to a personal computer > “os Before uploading the newly created program, the CPU module has to be connected to the personal computer using GX Works3, as outlined below: BEI NELSOFT Gx works (Untied Project) - [Module Corniguraton] Ea Project Edit Find/Replace Convert View Online Debug Diagnostics Tool Window Help I Module Configuration x Dispay Target iQ-R Series ‘Main Biase Eitension Base RQ Extension 8359 PLC CPU ‘Motion Controller CPU Power Supply Pre Se [The CPU module s now connected to the personal Ace lcomputer and is intial setting is completed. (aCRES cick to proceed to the next page. Ho replay, dick the button below. Reply, Cen(ELSEC-iQ-R_Series_Basics_na00166_eng el) fo rs Creating programs ) cao The example sorting system requires a control program in order to operate correctly. The correspondence between the control program and the operation of the external devices that are connected to the control system are shown below. End of animation Please cick J to proceed roche vert page To view agen, cick on the “Replay* bist: Replay HHH HT NN MeN ‘When the count reaches 7, the HiH— coummer ans ons : Number of cases Linen the counter 2 turns On, - that have passed ‘the counters Cl and C2 are Ls simultaneously reset. After the counters are reset, the ‘count starts again from 1.(@ 2-MELSEC~iQ-R_Series_Basics_na00166_eng eli ell Creating programs ) cao ‘The following shows the necessary steps for creating the sorting system control program. The animation shows how simple it is to implement the control tasks into program form. i] MELSOFT GX Works3 (Untitled Project) - [ProgPou [PRG] [LD] 23Step] Trois EGE Ardeplace Cowet view Onine Debug Diogrostcs Tee window Help Depey Tao: [AL =| [Output instruction | [MERCER Eeerea ®R DALTAP[1] Pulse conversior AR FFT] Bit device outpu aK UTI! —_Outinstructn ROUTE] Timers /Retent ® ourl2] Long timers / Le fre creshon cfs cntrel program has ew beam completed cick to proceed to the next page. replay cick the button bow. Output[@ L-MELSEC-iQ-R_Series_Basics_na00166_eng Register and executin: rams For the MELSEC iQ-R Series programmable controller be able to control the sorting system, the control program hhas to be uploaded to the CPU module. The necessary steps for this are as shown below: | 11 ovice Memory ee one ee Legend Dela Memory | ses | Feces Deviee/Lel Femory ( Boreas: Co Bitcun 50 NoeryOne 100/100% System Pxaneies Wire Completed z CFU Parner tne Covpited edule Pararcter Wing Coveted Ucal Label tial Uaue M2 Weng Completed Promam F k(Maihd Whine Coveted S&S Global Label taitial Value oO I _-@ ounne Pinnte te Le RAL 8484 Wt Geblaton (RE Local Label ntsl Vato | = & man 201708706 94828 Not Geaton | 0 Program i Fa su/on/os 408 Not Cabulatan ~ NANs 94688 Fe a Fe Wie Fle: ed [hen processne ends, close tho widow 9:44 replay. ‘lon Program upload and execution are now completed [click @_ to proceed to the next dlick the button below. Replay) |{ELSEC-iQ-R_Series_Basics_naO0166_eng eke (34 | Registering and executing programs ) cao For the MELSEC iQ-R Series programmable controller be able to control the sorting system, the control program hhas to be uploaded to the CPU module. The necessary steps for this are as shown below: Resetting the CPU module + ‘executing control programs ‘Stopoing the execution of the program Stopping the execution of the program P RUN LED turns off, and the execution of the control programs stops. cee | ERROR air EXD) org came)(@ 1-MELSEC-iQ-R_Series_Basics_na00165_eng soa Gali Operation of the sorting system ; nee The overall operation of the example sorting system is outlined below. Itis also possible to change the amount of crates that are sorted and to see how the control program changes. End of animation Toview the animation again with a diferent ‘number of conveyed cases, cick on the “Replay” button shown below. ena) cick D toprocead othe net page 4 Number of crates 1 : ‘When C2 turns ON, Cl and C2 are ‘ Shethaws passed ius rst L—__—__é 5) rT After the counters are rest the count starts agin from 2. ——La. — IWi 1-MELSEC-iQ-R_Series_Basice_na00166_eng Sa) —_ In this chapter, you have learned: + The general outline for programming + How to connect the CPU module to a personal computer + Creating control programs * Uploading the control program to the CPU module Important points to consider: 1L__ Creating programs for the control system ey 2. Uploading the control program to the CPU module 3._Executng the program Cece ad It is recommended to format the CPU module memory prior to using it for the fst time Coed ‘The control program is created using GX Warks3 programming software ‘Once the program has been uploaded to the CPU module, a hardware reset need to be ue initiated on the CPU module ‘The program stored inside the CPU module wil start executing once the CPU module Lee atin ‘operating switch has been set to "RUN"Wi 1-MELSEC-iQ-R_Series_Basice_na00166_eng Final Test Now that you have completed all of the lessons of the MELSEC iQ-R Series Basic course, you are ready to take the final test. If you are unclear on any of the topics covered, please take this opportunity to review those topics. There are a total of 5 questions (7 items) in this Final Test. You can take the final test as many times as you lke. How to score the test After selecting the answer, make sure to click the Answer button. Your answer will be lost if you proceed without clicking the Answer button. (Regarded as unanswered question) Score results The number of correct answers, the number of questions, the percentage of correct answers, and the pass/fail result «ill appear on the score page. ComectAnswers: 2 Total Questions 9 To pass the test, you have to ‘answer 60% of the questions correct. Percentage 2% Proceed Review Retry | *+ Click the Proceed button to exit the test. + Click the Review button to review the test. (Correct answer check) + Click the Retry button to retake the test again.(W@ 2-MELSEC~iQ-R_Series_Basics_na00166_eng ea al Test 1 coc © Input module © CPU module Power supply module © Extension base unit © Output module © Main base unit (answer | [Back |(W@ 2-MELSEC~iQ-R_Series_Basics_na00166_eng Sa) us jal Test 2 coc Base unit (CPU module ’ Power supply module ‘A Program capacit B Nuinber of requived modules Total consumption current of the required modules(W@ 2-MELSEC~iQ-R_Series_Basics_na00166_eng Sa) us jal Test 3 coc Programmable controllers have a robust design and can be installed in any environment. Programmable controllers can operate correctly when they are installed in environments as ‘described in the hardware specifications. | Answer BackWi 1-MELSEC-iQ-R_Series_Basice_na00166_eng ea al Test 4 coc © The two grounding terminals of the power supply module must always be grounded. © tis enough to ground one of the two grounding terminals of the power supply module.Wi 1-MELSEC-iQ-R_Series_Basice_na00166_eng ea jal Test 5 coc BCAD ‘A. Upload the control program to the CPU module 8B, Toggle the CPU module switch to “RUN” Reset the CPU module D. Format the CPU module memory [Answer | [BackWi 1-MELSEC-iQ-R_Series_Basice_na00166_eng Sa) ‘You have completed the Final Test, You results area as follows. ‘To end the Final Test, proceed to the next page. Correct answers: Total questions: | 5 Percentage : Oe Ea Es may] You failed the test. ico ayWi 1-MELSEC-iQ-R_Series_Basice_na00166_eng ‘You have completed the MELSEC i -R Series Basic Course. Thank you for taking this course. \We hope you enjoyed the lessons and the information you acquired in this course will be useful in the future. You can review the course as many times as you want. Review | Close |