Mitsubishi Electric MELSEC iQ-R Series User Manual

Mitsubishi Electric MELSEC iQ-R Series User Manual

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MELSEC iQ-R Process CPU Module
User's Manual
-R08PCPU
-R16PCPU
-R32PCPU
-R120PCPU
-R6RFM

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Summary of Contents for Mitsubishi Electric MELSEC iQ-R Series

  • Page 1 MELSEC iQ-R Process CPU Module User's Manual -R08PCPU -R16PCPU -R32PCPU -R120PCPU -R6RFM...
  • 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. If products are used in a different way from that specified by manufacturers, the protection function of the products may not work properly.
  • Page 4 [Design Precautions] WARNING ● Configure safety circuits external to the programmable controller to ensure that the entire system operates safely even when a fault occurs in the external power supply or the programmable controller. Failure to do so may result in an accident due to an incorrect output or malfunction. (1) Emergency stop circuits, protection circuits, and protective interlock circuits for conflicting operations (such as forward/reverse rotations or upper/lower limit positioning) must be configured external to the programmable controller.
  • Page 5 [Design Precautions] WARNING ● Especially, when a remote programmable controller is controlled by an external device, immediate action cannot be taken if a problem occurs in the programmable controller due to a communication failure. To prevent this, configure an interlock circuit in the program, and determine corrective actions to be taken between the external device and CPU module in case of a communication failure.
  • Page 6 [Design Precautions] CAUTION ● Do not install the control lines or communication cables together with the main circuit lines or power cables. Doing so may result in malfunction due to electromagnetic interference. Keep a distance of 100mm or more between those cables. ●...
  • Page 7 [Installation Precautions] WARNING ● Shut off the external power supply (all phases) used in the system before mounting or removing the module. Failure to do so may result in electric shock or cause the module to fail or malfunction. [Installation Precautions] CAUTION ●...
  • Page 8 Directly touching any conductive parts of the connectors while power is on may result in electric shock. *1 For details, please consult your local Mitsubishi Electric representative. [Wiring Precautions] CAUTION ● Individually ground the FG and LG terminals of the programmable controller with a ground resistance of 100 ohms or less.
  • Page 9 [Wiring Precautions] CAUTION ● Prevent foreign matter such as dust or wire chips from entering the module. Such foreign matter can cause a fire, failure, or malfunction. ● When a protective film is attached to the top of the module, remove it before system operation. If not, inadequate heat dissipation of the module may cause a fire, failure, or malfunction.
  • Page 10 [Startup and Maintenance Precautions] CAUTION ● When connecting an external device with a CPU module or intelligent function module to modify data of a running programmable controller, configure an interlock circuit in the program to ensure that the entire system will always operate safely. For other forms of control (such as program modification, parameter change, forced output, or operating status change) of a running programmable controller, read the relevant manuals carefully and ensure that the operation is safe before proceeding.
  • Page 11 [Startup and Maintenance Precautions] CAUTION ● Startup and maintenance of a control panel must be performed by qualified maintenance personnel with knowledge of protection against electric shock. Lock the control panel so that only qualified maintenance personnel can operate it. ●...
  • Page 12 Cautions When Using Mitsubishi Programmable Controllers or GOTs Connected to a Personal Computer With the RS-232/USB Interface (FA-A-0298) When the USB cable used is the GT09-C30USB-5P manufactured by Mitsubishi Electric, specific measures are not required to connect the AC-powered personal computer to the module. However, note that the signal ground (SG) is common for the module and its USB interface.
  • Page 13: Introduction

    Before using this product, please read this manual and the relevant manuals carefully and develop familiarity with the functions and performance of the MELSEC iQ-R series programmable controller to handle the product correctly. When applying the program examples provided in this manual to an actual system, ensure the applicability and confirm that it will not cause system control problems.
  • Page 14: Table Of Contents

    CONTENTS SAFETY PRECAUTIONS ..............1 INTRODUCTION .
  • Page 15 Precautions when the data logging function is used ..........61 Wiring .
  • Page 16 Standby type program ..............111 Execution type change .
  • Page 17 PART 6 FUNCTIONS CHAPTER 12 FUNCTION LIST CHAPTER 13 CLOCK FUNCTION 13.1 Time Setting ................185 Clock data .
  • Page 18 16.4 Remote RESET ............... . 223 Enabling remote RESET .
  • Page 19 20.12 SD Memory Card Replacement ............294 20.13 SD Memory Card Life When the Data Logging Function Is Used .
  • Page 20 CHAPTER 25 ROUTING SETTING 25.1 Setting Method............... . . 367 25.2 Setting Example.
  • Page 21 Precautions on writing data from GOT or external devices ........445 Precautions on outputting in the middle of the scan .
  • Page 22 27.11 Nesting (N) ................483 27.12 Pointer (P) .
  • Page 23 CHAPTER 32 CONSTANTS 32.1 Decimal Constant (K) ..............526 32.2 Hexadecimal Constant (H) .
  • Page 24 CHAPTER 36 ERROR CODES 36.1 Error Code System ..............550 36.2 Operation When an Error Occurs .
  • Page 25 Online module change function ............. 700 System information .
  • Page 26: Relevant Manuals

    This manual does not include information on the module function blocks. For details, refer to the Function Block Reference for the module used. e-Manual refers to the Mitsubishi Electric FA electronic book manuals that can be browsed using a dedicated tool.
  • Page 27: Terms

    TERMS Unless otherwise specified, this manual uses the following terms. Term Description Backup mode A mode to continue operation in a redundant system by switching the standby system to the control system when an error occurs in the control system. Buffer memory Memory in an intelligent function module for storing data such as setting values and monitored values.
  • Page 28: Generic Terms And Abbreviations

    • CC-Link IE Field Network master/local module • MELSECNET/H network module • MELSECNET/10 network module Power supply module A MELSEC iQ-R series power supply module Process CPU R08PCPU, R16PCPU, R32PCPU, R120PCPU Process CPU (process mode) A Process CPU operating in process mode.
  • Page 29: Part 1 Part Names

    PART 1 PART NAMES This part consists of the following chapters. 1 CPU MODULE 2 EXTENDED SRAM CASSETTE 3 REDUNDANT FUNCTION MODULE...
  • Page 30: Chapter 1 Cpu Module

    CPU MODULE This chapter describes the part names of the CPU module. The R08PCPU is used as an example. (13) (12) (11) (14) (15) (10) (21) (19) (18) (20) (17) (16) 1 CPU MODULE...
  • Page 31 Name Description READY LED Indicates the operating status of the CPU module and the error level. ( Page 533 LED status of the CPU module) ERROR LED ● READY LED-ERROR LED status On-off: Normal operation On-on: Minor error On-flashing: Moderate error Flashing-on: Minor error (Changing module online) Flashing (every 2s)-off: Initial processing Flashing (every 400ms)-off: Changing module online...
  • Page 32 Name Description (16) Battery A backup battery to hold clock data and to use the backup power function for the device/label memory (17) Battery connector pin A pin for connecting a lead wire of the battery (To save the battery, the lead wire is disconnected from the connector before shipment.) (18) Cassette cover A cover for the connector where an extended SRAM cassette is inserted (...
  • Page 33: Chapter 2 Extended Sram Cassette

    EXTENDED SRAM CASSETTE This chapter describes the part names of the extended SRAM cassette. Name Description Tab for cassette insertion/removal The part that is held when an extended SRAM cassette is inserted or removed ( Page 39 Inserting or Removing an Extended SRAM Cassette) 2 EXTENDED SRAM CASSETTE...
  • Page 34 MEMO 2 EXTENDED SRAM CASSETTE...
  • Page 35: Chapter 3 Redundant Function Module

    REDUNDANT FUNCTION MODULE This chapter describes the part names of the redundant function module. (10) (11) (12) (13) (14) Name Description RUN LED Indicates the operating status. On: Normal operation Flashing: Changing module online or executing a module communication test Off: Error (...
  • Page 36 Name Description (10) LINK LED Indicates the tracking communication status. On: Tracking communications being performed Off: Tracking communications not performed (11) L ERR LED Indicates the tracking communication error. On: Tracking communication error (one of the following) • A receive data is faulty (receive frame error). •...
  • Page 37: Part 2 Procedures Before Operation

    PART 2 PROCEDURES BEFORE OPERATION This part consists of the following chapters. 4 START-UP PROCEDURE 5 PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM...
  • Page 38: Chapter 4 Start-Up Procedure

    START-UP PROCEDURE This chapter describes the procedures before operation. Overview This section describes an outline of the procedure before operation for each CPU module. Procedure for process mode This section describes an outline of the procedure when using the Process CPU (process mode). The procedure for starting up a redundant system is partially different.
  • Page 39 Initializing the CPU module Initialize the CPU module using the engineering tool. ( Page 43 Initializing the CPU Module) Setting parameters The following table shows which parameters are required when changing the number of slots/the number of occupied points of a module, using an SD memory card, or using specific functions. When Required parameter Reference...
  • Page 40: Installing A Battery

    Installing a Battery Install a battery to the CPU module. Installation procedure Q6BAT The connector plug of the Q6BAT is disconnected from the jack of the CPU module before shipment. To use the battery, connect the connector plug of the Q6BAT and the jack of the CPU module by following the procedure below. Open the battery cover located on the bottom of the CPU module.
  • Page 41: Inserting Or Removing An Extended Sram Cassette

    Inserting or Removing an Extended SRAM Cassette Insert an extended SRAM cassette to the CPU module as needed. Insertion procedure Insert an extended SRAM cassette while the programmable controller is powered off. Open the cassette cover (1) located on the side of the CPU module.
  • Page 42: Inserting And Removing An Sd Memory Card

    Inserting and Removing an SD Memory Card Insert an SD memory card to the CPU module as needed. Insertion procedure Check the direction and insert an SD memory card, following the procedure below. Insert an SD memory card (1) into the card slot until it clicks with the notched edge in the direction as illustrated.
  • Page 43: Creating A Project

    Creating a Project Activate the engineering tool and create a project. [Project]  [New] Procedure Create a program, following the procedure below. The procedure is for the program described in ladder diagrams. Select "RCPU" in "Series", and the CPU module model to use in "Type". Then, select a programming language to use in the project in "Program".
  • Page 44: Connecting A Personal Computer

    Connecting a Personal Computer Connect a personal computer where an engineering tool has been installed to the CPU module. Procedure Connect a personal computer directly to the CPU module, following the procedure below. Connect a personal computer to the CPU module using a USB cable or Ethernet cable.
  • Page 45: Initializing The Cpu Module

    Initializing the CPU Module Initialize the CPU module. [Online]  [CPU Memory Operation] Procedure Select "Data Memory" on the "Memory Management" window, and click the [Initialization] button. Select "File Storage Area", and click the [Initialization] button. After the initialization processing completes, click the [Close] button.
  • Page 46 When the engineering tool is not connected to the actual system Set parameters by configuring a system manually on the Module Configuration window of the engineering tool. Select a base unit on the Element Selection window, and drag and drop it to the Module Configuration window. Drag and drop modules to be used on the base unit placed.
  • Page 47 Setting parameters from the Navigation window Set the following parameters from the Navigation window. ■System parameters These parameters need to be set from the Navigation window in the following cases: to change the number of slots on the base unit or the number of occupied points of the module; for a multiple CPU system; and for module synchronization operations.
  • Page 48: Programming

    Programming Create a program. This section describes how to create a program using the following program example. Program example • When Start1 turns on, Timer1 starts counting, and Lamp1 turns on. • When the current value of Timer1 reaches 1000, Lamp1 turns off. •...
  • Page 49: Inserting Program Elements

    Inserting program elements Drag and drop required program elements to the ladder editor. [Navigation window]  [Program]  [Scan]  [MAIN]  [ProgPou]  [ProgramBody] Procedure Insert a normally open contact of "Start1" in the program example, following the procedure below. Select a program element from the Element Selection window, and drag and drop (1) it to the desired position on the ladder editor.
  • Page 50 ■Inserting function blocks Insert function blocks, following the procedure below. Select a function block from the Element Selection window, and drag and drop it to the desired position on the ladder editor. The "FB Instance Name" window opens. Select the target label (global label or local label), and enter an instance name.
  • Page 51: Inserting Pous By Key Input

    Inserting POUs by key input POUs can be inserted by key input. Procedure Inserting a normally open contact of "Start1" in the program example, following the procedure below. Click the insertion position on the ladder editor, and press . Enter the name, "Start", in the entry field (1). Select "Start1" from the displayed list (2).
  • Page 52: Converting The Program

    4.10 Converting the Program Determine the input ladder blocks. Procedure Select [Convert]  [Convert] on the menu bar. When the conversion processing completes and the input ladder blocks are determined, the color of those ladder blocks changes from gray to white. 4.11 Saving the Project Save the created project.
  • Page 53: Resetting The Cpu Module

    4.13 Resetting the CPU Module Reset the CPU module using the RUN/STOP/RESET switch located on the front of the CPU module. Procedure Set the RUN/STOP/RESET switch (1) to the RESET position for a second or longer. Check that the ERROR LED (2) flashes for several times and turns off.
  • Page 54: Executing The Program

    4.14 Executing the Program Execute the program written to the programmable controller by using the RUN/STOP/RESET switch. Procedure Set the RUN/STOP/RESET switch (1) to the RUN position. Check that the PROGRAM RUN LED (P RUN) (2) turns on. 4 START-UP PROCEDURE 4.14 Executing the Program...
  • Page 55: Monitoring The Program

    4.15 Monitoring the Program Monitor the program operation using the engineering tool. Monitoring on the monitor status bar For the monitor status bar, refer to the following.  GX Works3 Operating Manual Monitoring on the ladder editor The on/off states of contacts and coils and the current values of word devices and labels can be monitored on the ladder editor.
  • Page 56: Chapter 5 Procedure For Starting Up A Redundant System

    PROCEDURE FOR STARTING UP A REDUNDANT SYSTEM This chapter describes the procedures for starting up a redundant system starting from the start-up procedure of CPU modules to execution of programs. Overview There are two ways to start up a redundant system. Start-up procedure Description Starting up both systems...
  • Page 57 Setting parameters Set system parameters, CPU parameters, and module parameters. ( Page 43 Setting Parameters) • To execute the functions that access the SD memory card, set memory card parameters. • When an intelligent function module is used in the system, set intelligent function module parameters. Users can set system parameters by loading the actual system configuration to the "Module Configuration"...
  • Page 58 Checking the connection of the extension cables When extension base units at extension level 2 and later are connected, check that the following LEDs are turned on. • CONNECT LED for the extension cable connected to the extension base unit •...
  • Page 59: Starting Up The Systems One By One

    Starting up the systems one by one To debug a program with only one system before operation, start up the control system. To start up the control system for a purpose other than debugging a program, start up the standby system to build a redundant system.
  • Page 60 Creating a program Create a program with the engineering tool. After creating the program, convert the program and save the project. ( Page 46 Programming) Writing the system A/B setting Set the system A or B using the engineering tool. ( Page 65 Setting the System (System A or System B)) Writing data to the programmable controller Write the set parameters and created programs to the CPU module using the engineering tool.
  • Page 61 Checking the LEDs Check that the LEDs of the CPU module and redundant function module are in the following states. The following figure shows the LED status when the own system is set as system A in the system settings. The CARD READY LED status (on or off) depends on whether an SD memory card is inserted to the CPU module or not.
  • Page 62 Starting up the standby system Start up the standby system while the control system keeps operating. Follow the steps 1 to 6 in the start-up procedure for the control system to start up the standby system. ( Page 57 Starting up the control system) Check that the two systems are exactly the same (modules on base units, their model names, and insertion status of the extended SRAM cassette or the SD memory card) before starting up the standby system.
  • Page 63: Precautions When The Data Logging Function Is Used

    • Collection interval and data to be collected in the data logging setting ( CPU Module Logging Configuration Tool Version 1 Operating Manual (MELSEC iQ-R Series)) • "Scan Time Monitoring Time (WDT) Setting" of the CPU parameter ( Page 200 Scan time monitoring time setting) When using the data logging function, note that the number of writings to the SD memory card is limited.
  • Page 64: Wiring

    Wiring Redundant function modules This section describes the wiring to redundant function modules. Wiring method Connect the tracking cables from the OUT connector of a redundant function module to the IN connector of the other redundant function module. For the specifications of the tracking cables connected to redundant function modules, refer to the following. Page 78 Redundant Function Module Connecting/disconnecting tracking cables ■Connection procedure...
  • Page 65: Redundant Extension Base Units

    Redundant extension base units For the wiring to redundant extension base units, refer to the following.  MELSEC iQ-R Module Configuration Manual Power supply modules in a redundant system This section describes the wiring to power supply modules. The terminal block of each power supply module has a screw size of M4. Wire cables to the terminal block with the applicable solderless terminal RAV1.25-4 or RAV2-4.
  • Page 66: Creating A Project

    Creating a Project Start up the engineering tool and create a project. [Project]  [New] Select the Process CPU to be used for "Type". Select "Redundant" for "Mode". Select a programming language to be used for "Programming Language" and click the [OK] button. Connecting a Personal Computer and the CPU Module Connect a personal computer on which the engineering tool has been installed to the CPU module of one system.
  • Page 67: Setting The System (System A Or System B)

    Setting the System (System A or System B) Set the system A or B using the engineering tool and write the system settings to the CPU module. [Online]  [Redundant PLC Operation]  [System A/B Setting] Setting procedure Set the CPU module to the STOP state. In the "System A/B Setting"...
  • Page 68 Checking method Check the LEDs of each redundant function module to check the system status. Setting of the engineering tool LED of the redundant function module System A System B When the setting is switched from "System A" to "System B" When the setting is switched to "System B", the SYS B LED flashes.
  • Page 69: Writing Data To The Programmable Controller

    Writing Data to the Programmable Controller Write the set parameters and created programs to the CPU module. [Online]  [Write to PLC] Operating procedure Select system parameters, CPU parameters, module parameters, and program files on the "Online Data Operation" window. When FBs are used, select the corresponding FB/FUN files.
  • Page 70: Monitoring The Program

    Monitoring the Program Check the operation of a program on the engineering tool. Change the connection destination with the engineering tool and check the operating status of the system A or B. [Online]  [Current Connection Destination] Select a system in "Specify Redundant CPU" on the "Specify Connection Destination Connection"...
  • Page 71: Part 3 System Configuration

    PART 3 SYSTEM CONFIGURATION This part consists of the following chapter. 6 SYSTEM CONFIGURATION...
  • Page 72: Chapter 6 System Configuration

    SYSTEM CONFIGURATION For system configurations using the MELSEC iQ-R series modules, applicable combinations of CPU modules and the other modules, the number of mountable modules, installation, and wiring, refer to the following.  MELSEC iQ-R Module Configuration Manual 6 SYSTEM CONFIGURATION...
  • Page 73 MEMO 6 SYSTEM CONFIGURATION...
  • Page 74 MEMO 6 SYSTEM CONFIGURATION...
  • Page 75: Part 4 Specifications

    PART 4 SPECIFICATIONS This part consists of the following chapter. 7 PERFORMANCE SPECIFICATIONS...
  • Page 76: Chapter 7 Performance Specifications

    PERFORMANCE SPECIFICATIONS CPU Module This section describes the specifications of the CPU module. Hardware specifications Item R08PCPU R16PCPU R32PCPU R120PCPU Operation control method Stored program cyclic operation I/O control mode Refresh mode (The direct access input/output is available by specifying the direct access input/ output (DX, DY).) Instruction LD instruction...
  • Page 77 Item R08PCPU R16PCPU R32PCPU R120PCPU Weight 0.20kg *1 The capacity of device area, label area, latch label area, and file storage area can be changed in parameter. The capacity of the device/ label memory can be increased by inserting an extended SRAM cassette. ( Page 142 Device/label memory area setting) *2 This is the total capacity of the device area and module label area.
  • Page 78: Programming Specifications

    Programming specifications Item R08PCPU R16PCPU R32PCPU R120PCPU Programming language • Ladder diagram (LD) *5*7*8 • Sequential function chart (SFC) • Structured text (ST) • Function block diagram (FBD/LD) Programming supporting function • Function block (FB) • Label programming (system/local/global) Program operation Execution type •...
  • Page 79 Item R08PCPU R16PCPU R32PCPU R120PCPU Number of system Special relay (SM) 4096 points (fixed) device points Special register (SD) 4096 points (fixed) Function input (FX) 16 points (fixed) Function output (FY) 16 points (fixed) 5 points  4 words (fixed) Function register (FD) Number of file File register (R/ZR)
  • Page 80: Extended Sram Cassette

    *1 The use of all the I/O signals is prohibited because they are used by the system. Optical fiber cables with connectors are available from Mitsubishi Electric System & Service Co., Ltd. (Catalogs of the optical fiber cables are also available.) •...
  • Page 81: Part 5 Cpu Module Operation

    PART 5 CPU MODULE OPERATION This part consists of the following chapters. 8 RUNNING A PROGRAM 9 CPU MODULE OPERATION PROCESSING 10 MEMORY CONFIGURATION OF THE CPU MODULE 11 BASIC CONCEPT OF REDUNDANT SYSTEM...
  • Page 82: Chapter 8 Running A Program

    RUNNING A PROGRAM Scan Configuration The following shows the scan configuration of the CPU module. In process mode The following shows the scan configuration of the CPU module in process mode. CPU module internal operation Structure of a scan Initial processing (when powered on or switched to RUN) I/O refresh Program execution END processing...
  • Page 83 In redundant mode This section describes the scan configurations of the CPU modules in a redundant system. In a redundant system, tracking transfer is performed in the END processing. ( Page 388 Tracking Transfer) However, in a redundant system with redundant extension base unit, tracking transfer is performed before the program operation.
  • Page 84: Initial Processing (When Powered On Or Switched To Run)

    Initial processing (when powered on or switched to RUN) For the initial processing (when powered on or switched to RUN), the following processes are performed: : Performed, : Not performed Item Initial processing Initial processing (when switched to RUN)  ...
  • Page 85: End Processing

    END processing The CPU module performs the following processing. • Network module link refresh • Intelligent function module refresh • Instruction end processing (including dedicated instruction for the module) • Device latch processing • Service processing suc