Mitsubishi MELSEC, QSCPU, QS User Manual

SAFETY PRECAUTIONS

(Always read these instructions before using this equipment.)

Before using this product, please read this manual, the relevant manuals introduced in this manual,

standard PLC manuals, and the safety standard carefully and pay full attention to safety to handle the product correctly.

In this manual, the safety instructions are ranked as "DANGER" and "CAUTION".

DANGER

CAUTION

Note that the CAUTION level may lead to a serious consequence according to the circumstances.

Always follow the instructions of both levels because they are important to personal safety.

Please save this manual to make it accessible when required and always forward it to the end user.

Indicates that incorrect handling may cause hazardous conditions, resulting in death or severe injury.

Indicates that incorrect handling may cause hazardous conditions, resulting in medium or slight personal injury or physical damage.

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[Design Precautions]

DANGER

When a safety PLC detects an error in an external power supply or a failure in PLC main module, it turns off all the outputs. Create an external circuit to securely stop the power of hazard by turning off the outputs.Incorrect configuration may result in an accident.

Create short current protection for a safety relay, and a protection circuit such as a fuse, and

breaker, outside a safety PLC.

When data/program change, or status control is performed from a PC to a running safety PLC, create an interlock circuit outside the sequence program and safety PLC to ensure that the whole system always operates safely. For the operations to a safety PLC, pay full attention to safety by reading the relevant manuals carefully, and establishing the operating procedure. Furthermore, for the online operations performed from a PC to a safety CPU module, the corrective actions against a communication error due to a cable connection fault, etc. should be predetermined as a system.

All output signals from a safety CPU module to the CC-Link Safety system master module are prohibited to use. These signals can be found in the CC-Link Safety System Master Module User's Manual. Do not turn ON or OFF these signals by sequence program, since turning ON/OFF these output signals of the PLC system may cause malfunctions and safety operation cannot be guaranteed.

When a safety remote I/O module has detected a CC-Link Safety error, it turns off all the outputs. Note that the outputs in a sequence program are not automatically turned off. If a CC-Link Safety error has been detected, create a sequence program that turns off the outputs in the program. If the CC-Link Safety is restored with the outputs on, it may suddenly operate and result in an accident.

To inhibit restart without manual operation after safety functions was performed and outputs were turned OFF, create an interlock program which uses a reset button for restart.

CAUTION

Do not bunch the wires of external devices or communication cables together with the main circuit or power lines, or install them close to each other.They should be installed 100 mm (3.94 inch) or more from each other.Not doing so could result in noise that would cause erroneous operation.

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[Installation Precautions]

CAUTION

Use a safety PLC in the environment that meets the general specifications described in this manual. Using this PLC in an environment outside the range of the general specifications could result in electric shock, fire, erroneous operation, and damage to or deterioration of the product.

While pressing the installation lever located at the bottom of module, insert the module fixing tab into the fixing hole in the base unit until it stops. Then, securely mount the module with the fixing hole as a supporting point. Incorrect loading of the module can cause a failure or drop. Secure the module to the base unit with screws. Tighten the screw in the specified torque range. If the screws are too loose, it may cause a drop of the screw or module. Over tightening may cause a drop due to the damage of the screw or module.

Completely turn off the externally supplied power used in the system before mounting or removingthe module. Not doing so could result in damage to the product.

Do not directly touch the module's conductive parts or electronic components. Doing so may cause malfunctions or a failure.

[Wiring Precautions]

DANGER

Be sure to shut off all phases of the external supply power used by the system before wiring. Not completely turning off all power could result in electric shock or damage to the product.

When energizing or operating the module after installation or wiring, be sure to close the attached terminal cover. Not doing so may result in electric shock.

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[Wiring Precautions]

CAUTION

Be sure to ground the FG terminals and LG terminals to the protective ground conductor. Not doing so could result in electric shock or erroneous operation.

Use a solderless terminal with insulation sleeve for wiring of a terminal block. Use up to two solderless terminals for a single terminal.

Use applicable solderless terminals and tighten them with the specified torque. If any solderlessspade terminal is used, it may be disconnected when the terminal screw comes loose, resultingin failure.

Wire the module correctly after confirming the rated voltage and terminal layout. Connecting a power supply of a different rated voltage or incorrect wiring may cause a fire or failure.

Tighten a terminal block mounting screw, terminal screw, and module fixing screw within the specified torque range. If the terminal block mounting screw or terminal screw is too loose, it may cause a short circuit, fire, or malfunctions. If too tight, it may damage the screw and/or the module, resulting in a drop of the screw or module, a short circuit or malfunctions. If the module fixing screw is too loose, it may cause a drop of the screw or module. Over tightening the screw may cause a drop due to the damage of the screw or module.

Be sure there are no foreign substances such as sawdust or wiring debris inside the module. Such debris could cause a fire, failure, or erroneous operation.

The module has an ingress prevention label on its top to prevent foreign matter, such as wire offcuts, from entering the module during wiring. Do not peel this label during wiring.Before starting system operation, be sure to peel this label because of heat dissipation.

Install our PLC in a control panel for use. Wire the main power supply to the power supply module installed in a control panel through a distribution terminal block. Furthermore, the wiring and replacement of a power supply module have to be performed by a maintenance worker who acquainted with shock protection. (For the wiring methods, refer to Section 10.3.)

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[Startup and Maintenance precautions]

DANGER

Do not touch the terminals while power is on. Doing so could cause shock or erroneous operation.

Correctly connect the battery.Also, do not charge, disassemble, heat, place in fire, short circuit, or solder the battery. Mishandling of battery can cause overheating or cracks which could result in injury and fires.

Turn off all phases of the external supply power used in the system when cleaning the module or retightening the terminal block mounting screws, terminal screws, or module fixing screws. Not doing so could result in electric shock.Tighten a terminal block mounting screw, terminal screw, and module fixing screw within the specified torque range. If the terminal block mounting screw or terminal screw is too loose, it may cause a short circuit, fire, or malfunctions. If too tight, it may damage the screw and/or the module, resulting in a drop of the screw or module, a short circuit or malfunctions. If the module fixing screw is too loose, it may cause a drop of the screw or module. Over tightening the screw may cause a drop due to the damage of the screw or module.

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[Startup and Maintenance precautions]

CAUTION

The online operations performed from a PC to a running safety PLC (Program change when a safety CPU is RUN, device test, and operating status change such as RUN-STOP switching) have to be executed after the manual has been carefully read and the safety has been ensured. Following the operating procedure predetermined at designing, the operation has to be performed by an instructed person. When changing a program while a safety CPU is RUN (Write during RUN), it may cause a program breakdown in some operating conditions. Fully understand the precautions described in the GX Developer's manual before use.

Do not disassemble or modify the modules. Doing so could cause a failure, erroneous operation, injury, or fire. If the product is repaired or remodeled by other than the specified FA centers or us, the warranty is not covered.

Use any radio communication device such as a cellular phone or a PHS phone more than 25cm(9.85 inch) away in all directions of the PLC. Not doing so can cause a malfunction.

Completely turn off the externally supplied power used in the system before mounting or removingthe module. Not doing so may result in a failure or malfunctions of the module.

Restrict the mounting/removal of a module, base unit, and terminal block up to 50 times (IEC61131-2-compliant), after the first use of the product. Failure to do so may cause the module to malfunction due to poor contact of connector.

Do not drop or give an impact to the battery mounted to the module. Doing so may damage the battery, causing the battery fluid to leak inside the battery. If the battery is dropped or given an impact, dispose of it without using.

Before touching the module, always touch grounded metal, etc. to discharge static electricity fromhuman body, etc. Not doing so may result in a failure or malfunctions of the module.

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[Disposal Precautions]

CAUTION

When disposing of this product, treat it as industrial waste. When disposing of batteries, separate them from other wastes according to the local regulations. (For details of the battery directive in EU member states, refer to Appendix 4.)

[Transportation Precautions]

CAUTION

When transporting lithium batteries, make sure to treat them based on the transport regulations. (For details of the controlled models, refer to Appendix 3.)

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REVISIONS

The manual number is given on the bottom left of the back cover.

Print Date Manual Number Revision

Sep., 2006 SH(NA)-080626ENG-A First edition

May, 2007 SH(NA)-080626ENG-B

Apr., 2008 SH(NA)-080626ENG-C

Sep., 2008 SH(NA)-080626ENG-D

Correction

Section 2.2, 4.1, 5.1, 6.1, 9.1.1, 9.1.3, 10.1, 10.3.1, 10.3.2, 12.2.1, 12.2.10

Addition

Section 12.2.12

Correction

ABOUT MANUALS, GENERIC TERMS AND ABBREVIATIONS, Section 1.1,

2.1, 4.2, 4.3, 4.4, 5.1, 5.3, 6.2, 8.1, 9.1.3, 9.1.4, 9.2.1, 10.2.1, 10.2.3, 10.3.1,

10.3.2, 11.1, 11.2, 12.2.1, 12.2.3, 12.2.4, 12.2.5, 12.2.7, 12.2.8, 12.2.9, 12.2.12,

12.3.1, 12.3.3, 12.3.4, 12.3.5, 12.3.6, 12.3.7, 12.3.8, 12.6, 12.7

Addition

Section 2.1.1, Appendix 2

Correction

Section 10.2.1

Addition

SAFETY PRECAUTIONS, Section 7.1, Appendix 4

Japanese Manual Version SH-080607-D

This manual confers no industrial property rights or any rights of any other kind, nor does it confer any patent licenses.

Mitsubishi Electric Corporation cannot be held responsible for any problems involving industrial property rights which may

occur as a result of using the contents noted in this manual.

2006 MITSUBISHI ELECTRIC CORPORATION

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INTRODUCTION

Thank you for choosing the Mitsubishi MELSEC-QS Series of Safety Programmable Controllers. Before using the equipment, please read this manual carefully to develop full familiarity with the functions

and performance of the QS series PLC you have purchased, so as to ensure correct use.

SAFETY PRECAUTIONS•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• A - 1

REVISIONS•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••A - 8

INTRODUCTION •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• A - 9

CONTENTS••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• A - 9

ABOUT MANUALS ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• A - 16

HOW THIS MANUAL IS ORGANIZED ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• A - 18

HOW TO USE THIS MANUAL ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• A - 20

GENERIC TERMS AND ABBREVIATIONS ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• A - 21

PRECAUTIONS FOR USE ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• A - 22

CHAPTER1 OVERVIEW 1 - 1 to 1 - 6

1.1 Features •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1 - 3

CHAPTER2 SYSTEM CONFIGURATION 2 - 1 to 2 - 6

2.1 System Configuration ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••2 - 1

2.1.1 Precautions for system configuration•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 2 - 3

2.2 Configuration of Peripheral Devices••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 2 - 4

2.3 Confirming Serial No. and Function Version••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 2 - 5

CHAPTER3 GENERAL SPECIFICATIONS 3 - 1 to 3 - 1

CHAPTER4 CPU MODULE 4 - 1 to 4 - 7

4.1 Performance Specifications••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 - 1

4.2 Part Names •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 - 3

4.3 Switch Operation after Writing a Program ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 - 5

4.4 Reset Operation••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4 - 6

CHAPTER5 POWER SUPPLY MODULE 5 - 1 to 5 - 5

5.1 Specifications •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 5 - 1

5.2 Precaution when connecting the uninterruptive power supply ••••••••••••••••••••••••••••••••••••••••••••• 5 - 3

5.3 Names of Parts and Settings ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 5 - 4

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CHAPTER6 BASE UNIT 6 - 1 to 6 - 2

6.1 Specification ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6 - 1

6.2 Part Names •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 6 - 2

CHAPTER7 BATTERY 7 - 1 to 7 - 2

7.1 Battery (Q6BAT) •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 7 - 1

7.1.1 Battery Specifications •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 7 - 1

7.1.2 Installation of Battery ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 7 - 2

CHAPTER8 CPU MODULE START-UP PROCEDURES 8 - 1 to 8 - 3

8.1 Procedure before Operating in SAFETY MODE •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 8 - 1

CHAPTER9 EMC AND LOW VOLTAGE DIRECTIVES 9 - 1 to 9 - 12

9.1 Requirements for Conformance to EMC Directive •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••9 - 1

9.1.1 Standards relevant to the EMC Directive ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9 - 1

9.1.2 Installation instructions for EMC Directive •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9 - 3

9.1.3 Cables •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••9 - 4

9.1.4 Power Supply Module ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••9 - 6

9.1.5 Others ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9 - 7

9.2 Requirement to Conform to the Low Voltage Directive •••••••••••••••••••••••••••••••••••••••••••••••••••••• 9 - 9

9.2.1 Standard applied for MELSEC-QS series PLC•••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9 - 9

9.2.2 MELSEC-QS series PLC selection •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9 - 9

9.2.3 Power supply••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9 - 10

9.2.4 Control panel ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9 - 10

9.2.5 Grounding••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9 - 12

9.2.6 External wiring ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 9 - 12

CHAPTER10 LOADING AND INSTALLATION 10 - 1 to 10 - 22

10.1 Calculating Heat Generation of PLC •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 10 - 3

10.2 Module Installation•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 10 - 5

10.2.1 Precaution on installation •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 10 - 5

10.2.2 Instructions for mounting the base unit ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••10 - 12

10.2.3 Installation and removal of module •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••10 - 15

10.3 Wiring ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••10 - 18

10.3.1 The precautions on the wiring •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••10 - 18

10.3.2 Connecting to the power supply module•••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••10 - 22

CHAPTER11 MAINTENANCE AND INSPECTION 11 - 1 to 11 - 10

11.1 Daily Inspection ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 11 - 3

11.2 Periodic Inspection ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 11 - 4

11.3 Battery Life and Replacement Procedure •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 11 - 5

11.3.1 Battery lives of CPU modules••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 11 - 6

11.3.2 Replacement Procedure of the CPU Module Battery •••••••••••••••••••••••••••••••••••••••••••••••• 11 - 8

A - 10

11.4 When PLC Has been Stored without a Battery ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 11 - 9

11.5 When Battery Has Gone Flat during Storage of a PLC•••••••••••••••••••••••••••••••••••••••••••••••••••11 - 10

CHAPTER12 TROUBLESHOOTING 12 - 1 to 12 - 86

12.1 Troubleshooting Basics •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 12 - 1

12.2 Troubleshooting Flowchart •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 12 - 2

12.2.1 Troubleshooting category flow •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 12 - 2

12.2.2 Flowchart for when the ERR terminal (negative logic) is off (opened) •••••••••••••••••••••••••••• 12 - 3

12.2.3 Flowchart for when the "POWER" LED turns off •••••••••••••••••••••••••••••••••••••••••••••••••••••• 12 - 5

12.2.4 When the "ALIVE" LED does not turn on or turns off •••••••••••••••••••••••••••••••••••••••••••••••• 12 - 7

12.2.5 Flowchart for when the "RUN" LED turns off •••••••••••••••••••••••••••••••••••••••••••••••••••••••••• 12 - 9

12.2.6 When the "RUN" LED flashes •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 10

12.2.7 Flowchart for when the "ERR." LED turns on or flashes••••••••••••••••••••••••••••••••••••••••••••12 - 11

12.2.8 When the "USER" LED turns on ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 14

12.2.9 When the "BAT." LED turns on ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 15

12.2.10 Flowchart for when a program cannot be read •••••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 16

12.2.11 Flowchart for when a program cannot be written ••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 17

12.2.12 Flowchart for when the CPU cannot communicate with the GX Developer•••••••••••••••••••••12 - 18

12.3 Error Code List •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 20

12.3.1 Error codes ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 21

12.3.2 Reading an error code ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 21

12.3.3 Error code list (1000 to 1999) ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 22

12.3.4 Error code list (2000 to 2999) ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 28

12.3.5 Error code list (3000 to 3999) ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 34

12.3.6 Error code list (4000 to 4999) ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 42

12.3.7 Error code list (5000 to 5999) ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 46

12.3.8 Error code list (8000 to 9000) ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 48

12.4 Canceling Errors •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 56

12.5 Error codes returned to request source during communication with CPU module ••••••••••••••••••12 - 58

12.6 Special Relay List••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 67

12.7 Special Register List ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••12 - 71

APPENDICES App- 1 to App - 7

Appendix 1 External Dimensions •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• App- 1

Appendix 1.1 CPU module •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• App- 1 Appendix 1.2 Power supply module••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• App- 2 Appendix 1.3 Main base unit ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• App- 3

Appendix 2 Safety CPU Module Upgrade ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• App- 4

Appendix 3 Precautions for Battery Transportation •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• App- 5

Appendix 4 Handling of Batteries and Devices with Built-in Batteries in EU Member States•••••••••••••• App- 6

Appendix 4.1 Disposal precautions ••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• App- 6 Appendix 4.2 Exportation precautions •••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••••• App- 7

INDEX Index- 1 to Index- 2

A - 11

(Related manual).................QSCPU User's Manual (Function Explanation, Program Fundamentals)

CONTENTS

SAFETY PRECAUTIONS

REVISIONS

INTRODUCTION

CONTENTS

ABOUT MANUALS

HOW TO SEE THIS MANUAL IS ORGANIZED

HOW TO USE THIS MANUAL

GENERIC TERMS AND ABBREVIATIONS

CHAPTER1 OVERVIEW

1.1 Features

1.2 Program Storage and Operation

1.3 Devices and Instructions Convenient for Programming

1.4 How to Check the Serial No. and Function Version

CHAPTER2 PERFORMANCE SPECIFICATION

CHAPTER3 SEQUENCE PROGRAM CONFIGURATION AND EXECUTION CONDITIONS

3.1 Sequence Program

3.1.1 Sequence program description method

3.1.2 Sequsence program operation

3.2 Concept of Scan Time

3.3 Operation Processing

3.3.1 Initial processing

3.3.2 CC-Link Safety, MELSECNET/H refresh

3.3.3 I/O refresh

3.3.4 END processing

3.4 RUN, STOP, PAUSE Operation Processing

3.5 Operation Processing during Momentary Power Failure

3.6 Data Clear Processing

3.7 Numeric Values which can be Used in Sequence Programs

3.7.1 BIN (Binary Code)

3.7.2 HEX (Hexadecimal)

3.7.3 BCD (Binary Coded Decimal)

CHAPTER4 I/O NUMBER ASSIGNMENT

4.1 Definition of I/O Number

4.2 Concept of I/O Number Assignment

A - 12

4.2.1 I/O numbers of base unit

4.2.2 I/O numbers of remote station

4.3 I/O Assignment by GX Developer

4.3.1 Purpose of I/O assignment by GX Developer

4.3.2 Concept of I/O assignment using GX Developer

4.3.3 Examples of I/O Number Assignment

4.4 Checking the I/O Numbers

CHAPTER5 MEMORIES AND FILES HANDLED BY CPU MODULE

5.1 Memories by CPU Module

5.1.1 Memory configuration and storable data

5.1.2 Program memory

5.1.3 Standard ROM

5.1.4 Standard ROM program execution (boot run) and writing

5.2 Program File Structure

5.3 File Operation by GX Developer and Handling Precautions

5.3.1 File operation

5.3.2 Precautions for handling files

5.3.3 Memory capacities of files

5.3.4 File size units

CHAPTER6 FUNCTIONS

6.1 Function List

6.2 Safety CPU Operation Mode

6.2.1 Safety CPU operation mode

6.2.2 Checking safety CPU operation mode

6.2.3 Safety CPU operation mode switching

6.2.4 Operation of each function in each safety CPU operation mode and CPU operation status

6.2.5 Online operations that can be executed on the CPU module from GX Developer

6.3 CPU access password

6.4 PLC memory initialization

6.5 Setting to prevent continuous RUN in TEST MODE

6.6 Checking the ROM write count

6.7 Self-diagnostics Function

6.7.1 LED display for error

6.7.2 Cancel the error

6.8 Recording the operation contents and self-diagnostics error occurrence contents (operation history function)

6.9 Constant scan

• error

6.10 Setting of Output (Y) Status when Changing between STOP and RUN

6.11 Clock Function

6.12 Remote Operation

6.12.1 Remote RUN/STOP

6.12.2 Remote RESET

A - 13

6.12.3 Relationship of remote operation and CPU's RUN/STOP status

6.13 Monitor Function

6.14 Writing in Program during CPU Module RUN

6.14.1 Online change in ladder mode

6.15 Watchdog Timer(WDT)

6.16 Remote password

6.17 CPU Module System Display by GX Developer

6.18 LED Display

6.18.1 Method to turn off the LED

CHAPTER7 COMMUNICATION WITH INTELLIGENT FUNCTION MODULE

7.1 Communication with CC-Link Safety master module

7.2 Communication with CC-Link IE Controller Network Module or MELSECNET/H Module

7.3 Communication with Ethernet Module

7.4 Communication using intelligent function module dedicated instructions

CHAPTER8 PARAMETERS

8.1 PLC Parameters

8.2 Network Parameters

8.3 Remote Password

CHAPTER9 DEVICE EXPLANATION

9.1 Device List

9.2 Internal User Devices

9.2.1 Input (X)

9.2.2 Output (Y)

9.2.3 Internal relay (M)

9.2.4 Annunciator (F)

9.2.5 Edge relay (V)

9.2.6 Link relay (B)

9.2.7 Link special relay (SB)

9.2.8 Timer (T)

9.2.9 Counter (C)

9.2.10 Data register (D)

9.2.11 Link register (W)

9.2.12 Link special register (SW)

9.3 Internal System Devices

9.3.1 Special relay (SM)

9.3.2 Special register (SD)

9.4 Nesting (N)

9.5 Constants

9.5.1 Decimal constant (K)

9.5.2 Hexadecimal constant (H)

A - 14

CHAPTER10 CPU MODULE PROCESSING TIME

10.1 Scan Time

10.1.1 Scan time structure

10.1.2 Time required for each processing included in scan time

10.1.3 Factors that increase the scan time

10.2 Other Processing Times

CHAPTER11 PROCEDURE FOR WRITING PROGRAM TO CPU MODULE

11.1 Items to be examined for program creation

11.2 Procedure for writing program

11.3 Boot run procedure

APPENDICES

Appendix 1 Special Relay List

Appendix 2 Special Register List

Appendix 3 List of Parameter No

Appendix 4 Restrictions on Using CC-Link IE Controller Network Module with Safety CPU Module

Appendix 5 Restrictions on Using MELSECNET/H Module with Safety CPU Module

Appendix 6 Restrictions on Using Ethernet Module with Safety CPU Module

Appendix 7 Dedicated Instructions which can be used in Safety CPU Module

Appendix7.1 List of dedicated instructions Appendix7.2 Programming using dedicated instructions

Appendix 8 Safety CPU Module Upgrade

Appendix 9 Access Range for Safety CPU Module

Appendix 10 Precautions for Battery Transportation

INDEX

A - 15

ABOUT MANUALS

Introduction Manual

Before constructing or designing the safety-related system, be sure to read the following manual.

Manual Name

Safety Application Guide

Explains the overview, construction method, laying and wiring examples, and application programs

of the safety-related system.

(Sold separately)

Related Manuals

The following manuals are also related to this product. If necessary, order them by quoting the details in the tables below.

Manual No.

(Model Code)

SH-080613ENG

(13JR90)

Manual Name

QSCPU User's Manual (Function Explanation, Program Fundamentals)

Explains the functions, programming methods, devices and others that are necessary to create

programs with the QSCPU.

(Sold separately)

QSCPU Programming Manual (Common Instructions)

Explains how to use the sequence instructions, basic instructions, application instructions, and

QSCPU dedicated instructions.

(Sold separately)

CC-Link Safety System Master Module User's Manual

Explains the specifications, procedures and settings before system operation, parameter setting,

and troubleshooting of the QS0J61BT12 CC-Link Safety system master module.

(Sold separately)

CC-Link Safety System Remote I/O Module User's Manual

Explains the specifications, procedures and settings before system operation, parameter setting,

and troubleshooting of the CC-Link Safety system remote I/O module.

(Sold separately)

CC-Link IE Controller Network Reference Manual

Explains the specifications, procedures and settings before system operation, parameter setting,

programming, and troubleshooting of a CC-Link IE controller network.

(Sold separately)

Q Corresponding MELSECNET/H Network System Reference Manual (PLC to PLC

network)

Explains the specifications, procedures and settings before system operation, parameter setting,

programming, and troubleshooting of a MELSECNET/H network system for PLC to PLC network.

(Sold separately)

Q Corresponding Ethernet Interface Module User's Manual (Basic)

Explains the specifications, procedures for data communication with external devices, line

connection (open/close), fixed buffer communication, random access buffer communication, and

troubleshooting of the Ethernet module.

(Sold separately)

Q Corresponding Ethernet Interface Module User's Manual (Application)

Explains the e-mail function, programmable controller CPU status monitoring function,

communication function via CC-Link IE controller network, MELSECNET/H or MELSECNET/10,

communication function using the data link instructions, file transfer function (FTP server) of the

Ethernet module.

(Sold separately)

Manual No.

(Model Code)

SH-080627ENG

(13JR93)

SH-080628ENG

(13JW01)

SH-080600ENG

(13JR88)

SH-080612ENG

(13JR89)

SH-080668ENG

(13JV16)

SH-080049

(13JF92)

SH-080009

(13JL88)

SH-080010

(13JL89)

A - 16

Manual Name

Q Corresponding MELSEC Communication Protocol Reference Manual

Explains the communication methods and control procedures using the MC protocol, which is used

by external devices to read and write data of the programmable controller CPU via the serial

communication module or Ethernet module.

(Sold separately)

GX Developer Version 8 Operating Manual

Explains the online functions of GX Developer, such as the programming, printout, monitoring, and

debugging methods.

(Sold separately)

GX Developer Version 8 Operating Manual (Safety Programmable Controller)

Explains the GX Developer functions added and modified for the compatibility with the safety

programmable controller.

(Sold separately)

Remark

Printed materials are separately available for single item purchase. Order the manual by quoting the manual number on the table above (Model code).

Manual No.

(Model Code)

SH-080008

(13JF89)

SH-080373E

(13JU41)

SH-080576ENG

(13JU53)

A - 17

HOW THIS MANUAL IS ORGANIZED

Reference destination

A reference destination or

reference manual is marked

Chapter heading

The index on the right side of the page

shows the chapter of the open page at a

glance.

A - 18

Section title

The section of the open page is shown at a glance.

In addition, this manual provides the following explanations.

POINT

Explains the matters to be especially noted, the functions and others related to the description on that page.

Remark

Provides the reference destination related to the description on that page and the convenient information.

A - 19

HOW TO USE THIS MANUAL

This manual is prepared for users to understand the hardware specifications of those modules such as the CPU modules, power supply modules, and base units, maintenance and inspections of the system, and troubleshooting required when you use QS series PLCs.

The manual is classified roughly into three sections as shown below.

1) Chapters 1 and 2 Describe the outline of the CPU module and the system

2) Chapters 3 to 7 Describe the general specifications indicating the operating

3) Chapters 8 to 12 Describe the overall maintenance such as the installation of the

configuration. The basics of the system configuration of CPU module are described.

environments of the CPU module, power supply module, and base units, and the performance specifications of these modules.

CPU module, daily inspections, and troubleshooting.

Remark

This manual does not explain the functions of the CPU module. For these functions, refer to the manual shown below.

QSCPU User's Manual (Function Explanation, Program Fundamentals)

A - 20

GENERIC TERMS AND ABBREVIATIONS

Unless otherwise specified, this manual uses the following generic terms and abbreviations to explain the QS series CPU modules.

Generic Term/Abbreviation Description

Safety PLC

Standard PLC

QS series Abbreviation for Mitsubishi safety PLC MELSEC-QS series

QS001CPU Abbreviation for the QS001CPU type safety CPU module

CPU module Other name for the QS001CPU

GX Developer

QS034B Abbreviation for the QS034B type safety main base unit

Base unit Other name for the QS034B

QS061P Abbreviation for the QS061P-A1 and QS061P-A2 type safety power supply modules

Power supply module Other name for the QS061P

QS0J61BT12 Abbreviation for the QS0J61BT12 type CC-Link Safety system master module

CC-Link Safety Abbreviation for the CC-Link Safety system

CC-Link Safety master module Other name for the QS061BT12

CC-Link IE controller network

module

MELSECNET/H Abbreviation for the MELSECNET/H network system

MELSECNET/H module

Ethernet Abbreviation for the Ethernet network system

Ethernet module

Intelligent function module

QS0J65BTS2-8D Abbreviation for the QS0J65BTS2-8D CC-Link Safety remote I/O module

QS0J65BTS2-4T Abbreviation for the QS0J65BTS2-4T CC-Link Safety remote I/O module

QS0J65BTB2-12DT Abbreviation for the QS0J65BTB2-12DT type CC-Link Safety remote I/O module

CC-Link Safety remote I/O

module

Q series CPU module

Standard CPU module

Battery Abbreviation for the Q6BAT type battery

Blank cover Abbreviation for the QG60 type blank cover

GOT

Generic term for safety CPU module, safety power supply module, safety main base

unit, CC-Link safety master module and CC-Link safety remote I/O module.

Generic term of each module for MELSEC-Q series, MELSEC-QnA series, MELSEC-A

series and MELSEC-FX series. (Used for distinction from safety PLC.)

General product name for the models SW8D5C-GPPW-E, SW8D5C-GPPW-EA,

SW8D5C-GPPW-EV and SW8D5C-GPPW-EVA

Abbreviation for the QJ71GP21-SX and QJ71GP21S-SX CC-Link IE controller network

module

Abbreviation for the QJ71LP21-25, QJ71LP21S-25, QJ71LP21G, QJ71BR11

MELSECNET/H network module

Abbreviation for the QJ71E71-100, QJ71E71-B5, QJ71E71-B2 Ethernet interface

module

Generic term for the CC-Link Safety master module, CC-Link IE controller network

module, MELSECNET/H module, and Ethernet module

Generic term for the QS0J65BTS2-8D, QS0J65BTS2-4T, QS0J65BTB2-12DT

Generic term for the Q00JCPU, Q00CPU, Q01CPU, Q02CPU, Q02HCPU, Q06HCPU,

Q12HCPU, Q25HCPU, Q12PHCPU, Q25PHCPU, Q12PRHCPU and Q25PRHCPU

modules

Other name for the Q series CPU module (Used for distinction from safety CPU

modules.)

Generic term for the Mitsubishi Graphic Operation Terminal GOT-A*** series, GOT-F***

series and GOT1000 series

A - 21

PRECAUTIONS FOR USE

Precautions for the first use of Q series a CPU module

Precautions on battery

(1) When running the CPU module that has been stored without battery

(2) When running the CPU module that has been stored with battery longer than

When using a CPU module for the first time, the PLC memory needs to be initialized using GX Developer. For details of PLC memory initialization, refer to the following manual.

GX Developer Operating Manual (Safety PLC)

When, in the TEST MODE, running the CPU module that has been stored with the battery removed, the memory needs to be formatted using GX Developer.

( Section 11.4)

the battery life

When, in the TEST MODE, running the CPU module that has been stored with the battery exceeding its life, the memory needs to be formatted using GX Developer.

( Section 11.5)

A - 22

OVERVIEW

CHAPTER1 OVERVIEW

This Manual describes the hardware specifications and handling methods of the QS Series CPU Module QS001CPU. The Manual also includes descriptions related to the specifications of the power supply module, base unit and battery.

For the functions, programs, and devices of the QS Series CPU Module, refer to the manual below.

QSCPU User's Manual (Function Explanation, Program Fundamentals)

OVERVIEW

SYSTEM

CONFIGURATION

GENERAL

SPECIFICATIONS

CPU MODULE

POWER SUPPLY

MODULE

BASE UNIT

1 - 1

BATTERY

CPU MODULE START-

UP PROCEDURES

OVERVIEW

(1) List of QS Series CPU Module manuals

The QS series CPU module manuals are as shown below. For details such as manual numbers, refer to "About Manuals" in this manual.

Table1.1 List of manuals of QS Series CPU module

Purpose

Confirmation of part names and

specifications of the CPU module

Confirmation of connection methods

for the power supply module,and base

unit

Construction of the CPU system

(confirmation of start-up procedure

and I/O number assignment)

Confirmation of the sequence program

configuration and memory

Hard ware

(Packed)

QSCPU CPU Module User's Manual (Hardware)

Outline

Maintenance

and Inspection

QSCPU User's Manual (Hardware Design, Maintenance and inspection)

Details

Program

Fundamentals

QSCPU User's Manual (Function Explanation, Program Fundamentals)

Outline

Details

Common

Instructions

QSCPU Programming Manual (Common Instruction)

Confirmation of the functions,

parameters, and devices of the CPU

module

Confirmation of the troubleshooting

and error codes

Confirmation of usage of sequence

instructions, basic instructions,

application instructions, etc.

Details

1 - 2

OVERVIEW

1.1 Features

The QS series CPU module has the following new features:

(1) Safety PLC system can be constructed

The QS series programmable controllers have obtained the highest safety level (IEC61508 SIL3, EN954-1/ISO13849-1 Category 4, IEC62061) applicable to programmable controllers.

Power supply/CPU/CC-Link Safety master module

OVERVIEW

SYSTEM

CONFIGURATION

GX Developer (Version 8.40S or later)*1

Standard remote I/O station

CC-Link Safety

Standard Remote device station

Figure 1.1 Safety PLC system

CC-Link Safety remote I/O station

Emergency stop switch

CC-Link Safety remote I/O station

Emergency stop switch

Light curtain

CC-Link Safety remote I/O station

Safety relay

GENERAL

SPECIFICATIONS

CPU MODULE

POWER SUPPLY

MODULE

* 1 : The available functions vary depending on the versions. For details, refer to Appendix 2.

1.1 Features

1 - 3

BASE UNIT

BATTERY

CPU MODULE START-

UP PROCEDURES

OVERVIEW

(2) The safety CPU operation mode is equipped for safe system operation

The CPU module is equipped with two safety CPU operation modes. "SAFETY MODE" for safe system operation and "TEST MODE" for system construction and maintenance. These two modes prevent the user's erroneous operations for safe system operation.

(a) SAFETY MODE

SAFETY MODE is a mode for safe system operation. This mode prohibits the write operation from a programming tool and the device test operation during the system operation.

(b) TEST MODE

TEST MODE is a mode for maintenance. This mode enables the write operation from a programming tool and the device test operation to debug or maintain the sequence program.

For the details of operations available in the SAFETY MODE and TEST MODE, refer to the following manual.

QSCPU User's Manual (Function Explanation, Program Fundamentals)

(3) Enriched operation history and error history

The CPU module can record a total of 3000 details of the CPU module operation by the user and errors occurred in the CPU module or CC-Link Safety as operation/error history data. Recording the details of the CPU module operation by the user into the operation/ error history clarifies the occurrence order of operations and errors. Troubleshooting becomes easier by confirming the operation/error history.

The contents recorded in the operation/error history are shown in Table1.2.

Table1.2 Recorded contents of operation/error history

Information Contents History Information per Entry

• Operation code

• Operation message

• Operation execution date

• Result code

• Operation attached information

• Error code

• Error message

• Occurrence date

• Error information category (common

information/individual information)

• Error information (common

information/individual information)

Operation

history

information

Error history

information

User's operations for the CPU module are

stored as a history.

(Operations which change the CPU module

status are recorded.)

The following errors are stored as a history.

• Error/failure detected by self-diagnostics

• Hardware error

• Error detected by CC-Link Safety

1 - 4

1.1 Features

OVERVIEW

(4) Enhanced RAS

(a) Enhanced memory diagnostics

The memory diagnostics equipped with the CPU module are enhanced.

(b) Redundant CPU

The CPU module has two CPUs (CPU A and CPU B). The operation results of CPU A/CPU B are compared, and output only when the results are matched so that incorrect outputs can be prevented. (When the compared results are mismatched, the system stops.)

CPU module

OVERVIEW

SYSTEM

CONFIGURATION

CPU

Operation

result

Figure 1.2 Redundant CPU

The diagnostic functions of the Table1.3 prevents incorrect outputs when a

hardware error which cannot be detected by the OS occurs.

Table1.3 Hardware diagnostics function added to the QS series CPU module

Diagnostics Diagnosis Contents

Overvoltage/

undervoltage detection

Clock stop detection The input clock stop to the CPU module internal circuit is detected.

Overvoltage or undervoltage is detected for the power supply voltage

provided from the power supply module to the CPU module.

Compare

CPU

Operation

result

Output when matched

GENERAL

SPECIFICATIONS

CPU MODULE

POWER SUPPLY

MODULE

1.1 Features

1 - 5

BASE UNIT

BATTERY

CPU MODULE START-

UP PROCEDURES

OVERVIEW

(5) USB interface is equipped

(6) Connectable with personal computers and standard programmable controllers

The CPU module is equipped with the USB interface to communicate with a programming tool.

USB

Personal compute

Figure 1.3 Connection to a personal computer using USB

The CPU module can read data from the MELSOFT products installed in the personal computer and also can communicate data between safety programmable controller and standard programmable controller using dedicated instructions via CC-Link IE

controller network, MELSECNET/H, and/or Ethernet Besides, the data of ladder monitor, device monitor, and operation/error history in the safety programmable controller can be read using GOT.

1 - 6

1.1 Features

Personal compute

Figure 1.4 Connection with personal computer and standard programmable controller

* 1 : For an access range from GX Developer and a GOT to a safety CPU module, refer to the following

manual.

QSCPU User's Manual (Function Explanation, Program Fundamentals)

* 2 : An access to the CPU module can be restricted by using the remote password function.

SYSTEM CONFIGURATION

CHAPTER2 SYSTEM CONFIGURATION

This section describes the system configuration of the QS series CPU module cautions on use of the system, and configured equipment.

2.1 System Configuration

The following figure shows the system configuration of the safety PLC system when the QS series CPU module is used.

(1) System configuration when the CPU(QS001CPU) is used

OVERVIEW

SYSTEM

CONFIGURATION

GENERAL

SPECIFICATIONS

Battery for a CPU

(Q6BAT)

QS001CPU CPU module

QS034B base unit

Power supply/intelligent function module

Figure 2.1 System configuration

* 1 : For mountable modules, refer to Section 2.1.1 "Precautions for system configuration".

CPU MODULE

POWER SUPPLY

MODULE

BASE UNIT

2.1 System Configuration

2 - 1

BATTERY

CPU MODULE START-

UP PROCEDURES

SYSTEM CONFIGURATION

(2) System configuration overview

Table2.1 Base unit and power supply module applicable to system configuration

Base unit model name QS034B

Maximum number of monted

modules

Power supply module model

name

Base unit (QS034B)

CPU 0 1 2 3

00 to 0F

CPU modulePower supply module

Figure 2.2 System configuration

QS061P-A1, QS061P-A2

10 to 1F

20 to 2F

4 modules

Slot numbe

I/O number

30 to 3F

Precautions

• The extension base unit cannot be connected.

• The multiple CPU system cannot be configured.

• The modules which can be mounted on the I/O slot are the CC-Link Safety master module, CC-Link IE controller network module, MELSECNET/H module, Ethernet module, and blank cover only. If a module other than the ones mentioned above is mounted, "MODULE LAYOUT ERROR" (error code: 2125) is detected. Note, however, that a "MODULE LAYOUT ERROR" is not detected for the slot where "Empty" has been set in the I/O assignment setting of PLC parameter.

• GOTs cannot be connected.

2 - 2

2.1 System Configuration

SYSTEM CONFIGURATION

2.1.1 Precautions for system configuration

(1) Modules mountable on the main base unit

Table2.2 lists the modules that can be mounted on the main base unit. The number of mounted modules and functions are restricted depending on the module type.

Table2.2 Modules mountable on the main base unit

Module Model

CPU module • QS001CPU Only one ---

Power supply module

CC-Link Safety master

module

CC-Link IE controller network

module

MELSECNET/H module

Ethernet module

Blank cover • QG60 Up to four ---

• QS061P-A1

• QS061P-A2

• QS0J61BT12 Up to two ---

• QJ71GP21-SX

• QJ71GP21S-SX

• QJ71LP21-25

• QJ71LP21S-25

• QJ71LP21G

• QJ71LP21GE

• QJ71BR11

• QJ71E71-B2

• QJ71E71-B5

• QJ71E71-B100

Number of modules

mounted in one system

Only one (only one of the module

models)

Only one (only one of the models

among CC-Link IE controller network

modules and MELSECNET/H

modules)

Only one (only one of the module

models)

Remarks

• The first five digits of the serial

number are “10041” or higher

• Function version D or later

---

OVERVIEW

SYSTEM

CONFIGURATION

GENERAL

SPECIFICATIONS

CPU MODULE

2.1 System Configuration

2.1.1 Precautions for system configuration

2 - 3

POWER SUPPLY

MODULE

BASE UNIT

BATTERY

CPU MODULE START-

UP PROCEDURES

SYSTEM CONFIGURATION

2.2 Configuration of Peripheral Devices

This section describes the configuration of the peripheral devices usable in the safety PLC system.

QS001CPU

Personal computer (GX Developer Version 8.40S or later)

USB cable*1

* 1: For details of the USB cable, refer to "About the USB cable (QCPU (Q mode) compatible)" of the

following manual.

GX Developer Operating Manual

Figure 2.3 Configuration of peripheral devices

2 - 4

2.2 Configuration of Peripheral Devices

2.1.1 Precautions for system configuration

SYSTEM CONFIGURATION

2.3 Confirming Serial No. and Function Version

The serial No. and function version of the CPU module can be confirmed on the rated plate and GX Developer's system monitor.

OVERVIEW

(1) Confirming the serial No. on the rated plate

The rated plate is situated on the side face of the CPU module.

PASSED

MODEL

Serial No. (first 5 digits)

function version

SERIAL

080910000000000-A

Standard symbol for conformance is described.

MADE IN JAPAN

Figure 2.4 The rated plate

(2) Checking on the front of the module

The serial number written on the rating plate is displayed on the front (at the bottom)

of the module.

SYSTEM

CONFIGURATION

GENERAL

SPECIFICATIONS

CPU MODULE

Q S 0 0 1 C P U

A L I V E

R U N E R R.

PULL

U S B

T E S T U S E R B A T.

Figure 2.5 CPU module front display

090911090910001-B

Serial No.

POWER SUPPLY

MODULE

BASE UNIT

BATTERY

2.3 Confirming Serial No. and Function Version

2 - 5

CPU MODULE START-

UP PROCEDURES

SYSTEM CONFIGURATION

Remark

The serial number is displayed on the front of the module from March 2008 production. Products manufactured during switching period may not have the serial number on the front of the module.

(3) Confirming the serial No. on the system monitor (Product Information List)

To display the System monitor screen, select [Diagnostics] [System monitor] and click the Product Information List button in GX Developer. On the system monitor, the serial No. and function version of the intelligent function module can also be confirmed.

Serial number function version

2 - 6

Figure 2.6 System monitor

POINT

The serial number displayed on the Product information list screen of GX Developer may differ from that on the rating plate and on the front of the module.

• The serial No. on the rated plate describes the management information of the product.

• The serial No. displayed on the product information of GX Developer describes the function information of the product. The function information of the product is updated when adding functions.

2.3 Confirming Serial No. and Function Version

GENERAL SPECIFICATIONS

CHAPTER3 GENERAL SPECIFICATIONS

The performance specifications of PLC are shown in Table3.1.

Table3.1 General specifications

Item Specifications

Operating ambient

temperature

Storage ambient

temperature

Operating ambient

humidity

Storage ambient

humidity

Conforming

Vibration

resistance

Shock resistance

Operating

ambience

Operating

altitude

Installation location Inside control panel

Overvoltage

CHAPTER4 CPU MODULE

4.1 Performance Specifications

Table4.1 shows the performance specifications of the CPU module.

Table4.1 Performance Specifications

Item QS001CPU Remarks

Control method Repetitive operation of stored program ----

I/O control mode Refresh mode ---Program

language Processing speed

(sequence

instruction) Constant scan

(Function for keeping regular scan

time)

Program capacity

Memory

capacity

Max. number of

files stored

Sequence control

language

LD X0

MOV D0 D1

Program memory

(drive 0)

Standard ROM

(drive 4)

Program memory

Standard ROM

Relay symbol language, function block. ----

0.10 s

0.35 s

1 to 2000ms

(Setting available in1ms unit.)

14k steps

(56k bytes)

128k bytes ----

----

Setting by parameters.

----

No. of times of writing data into the

standard ROM

No. of I/O device points 6144 points(X/Y0 to 17FF)

No. of I/O points 1024 points(X/Y0 to 3FF)

*1 : The maximum number of executable sequence steps is as shown below.(Program capacity) - (File heade size (default: 34 steps))

For the details, refer to the manual below.

QSCPU User's Manual (Function Explanation, Program Fundamentals)

*2 : Each of parameter, sequence program, SFC program, and device comment files can be stored.

Max.100000 times ----

No. of points

usable on

program

No. of points

accessible to the

actual I/O module

4 - 1

4.1 Performance Specifications

CPU MODULE

Table4.1 Performance Specifications (Continue)

Item QS001CPU Remarks

Internal relay [M] 6144 points by default (M0-6143) (changeable)

Link relay [B] 2048 points by default (B0 to 7FF) (changeable)

512 points by default (T0 to 511) (changeable)

(Sharing of low- and high-speed timers)

The low- and high-speed timers are specified by the instructions.

Timer [T]

Retentive timer [ST]

No. of device points

Counter [C] Normal counter: 512 points by default (C0 to 511) (changeable)

Data register [D] 6144 points by default (D0 to 6143) (changeable)

Link register [W] 2048 points by default (W0 to 7FF) (changeable)

Annunciator [F] 1024 points by default (F0 to 1023) (changeable)

Edge relay [V] 1024 points by default (V0 to 1023) (changeable)

Link special relay [SB] 1536 points (SB0 to 5FF)

Link special register [SW] 1536 points (SW0 to 5FF)

Special relay [SM] 5120 points (SM0 to 5119)

Special register [SD] 5120 points (SD0 to 5119)

RUN/PAUSE contact

Timer function

Allowable instantaneous power failure

period

5VDC internal current consumption 0.43A ----

H 98mm (3.86inch) ----

External dimensions

Weight 0.29kg ----

Protection of degree IP2X ----

W 55.2mm (2.17inch) ----

D 113.8mm (4.48inch) ----

The measurement unit of the low- and high-speed timers is set up by

parameters.

(Low-speed timer: 1 to 1000ms, 1ms unit, 100ms by default)

(High-speed timer: 0.1 to 100ms, 0.1ms unit, 10ms by default)

0 point by default

(sharing of the low- and high-speed retentive timers) (changeable)

The low- and high-speed retentive timers are specified

by the instructions.

The measurement unit of the low- and high-speed retentive timers

is set up by parameters.

(Low-speed retentive timer: 1 to 1000ms, 1ms unit, 100ms by default)

(High-speed retentive timer: 0.1 to 100ms, 0.1ms unit, 10ms by default)

One contact can be set up in X0 to 17FF for each of RUN. No PAUSE

contact.

Year, month, date, hour, minute, second and day-of-week

(leap year automatically identified)

Accuracy: -3.18 to +5.25s (TYP.+2.14s)/d at 0

Accuracy: -3.18 to +2.59s (TYP.+2.07s)/d at 25

Accuracy: -12.97 to +3.63s (TYP.-3.16s)/d at 55

Varies depending on the power supply module. ----

The number of points

can be changed within

the setting range.

( QSCPU User's

Manual

(Function

Explanation,

Program

Fundamentals)

The number of device points is fixed.

Setting by parameters.

----

OVERVIEW

SYSTEM

CONFIGURATION

GENERAL

SPECIFICATIONS

CPU MODULE

POWER SUPPLY

MODULE

BASE UNIT

Remark

For the general specifications, refer to CHAPTER 3.

4.1 Performance Specifications

4 - 2

BATTERY

CPU MODULE START-

UP PROCEDURES

W y

CPU MODULE

4.2 Part Names

QS001CPU

hen opening the cover, put

our finger here.

ALIVE

RUN

ERR.

PULL

USB

TEST USER BAT.

15)

13)

14)

10)

ALIVE

RUN

ERR.

TEST USER BAT.

BAT.

RESET RUN

PULL

STOP

Figure 4.1 Front face Figure 4.2 With front cover open

11)

12)

Figure 4.3 Side Face

4 - 3

4.2 Part Names

(

)

CPU MODULE

No. Name Application

1) Module fixing hook Hook used to fix the module to the base unit.

"ALIVE" LED

2) (Green)

"TEST" LED

3) (Yellow)

"RUN" LED

4) (Green)

"ERR." LED

5) (Red)

On : Off : When the hardware watchdog timer error is detected

Indicates the operating mode of the CPU module.

On : Flash : When TEST MODE is switched to SAFETY MODE

Off : SAFETY MODE

Indicates the operating status of the CPU module.

On : Off : During stop in "STOP" or when the error which stops the operation is detected

Flash : When parameters/program is written during STOP and the RUN/STOP/RESET

On :

Off : Normal Flash : When the self-diagnostics error that will stop operation is detected

Table4.2 Part Names

Normal

("ERR." LED is On.)

TEST MODE

The "TEST" LED turns off after reset.

(Flash interval: On 200ms/Off 200ms)

During operation in "RUN"

switch is moved from "STOP" to "RUN"

(Flash interval: On 200ms/Off 200ms)

When the self-diagnostics error that will not stop operation, other than a battery

error, is detected

(Flash interval: On 200ms/Off 200ms)

When the reset operation is performed

(Flash interval: On 60ms/Off 60ms)

OVERVIEW

SYSTEM

CONFIGURATION

GENERAL

SPECIFICATIONS

CPU MODULE

"USER" LED

6) (Red)

"BAT." LED

7) (Yellow)

8) Module loading lever Used to load the module to the safety base unit.

USB connector

10)

RUN/STOP/RESET switch

11) Module fixing screw Screw used to fix a module to the base unit. (M3 screw)

12) Module fixing latch Latch used to fix a module to the base unit.

13) Battery Backup battery for the power failure compensation function of program memory.

14) Battery connector pin

15) Serial number display Displays the serial number on the rating plate.

*1 : Turns On during the initial processing (self-diagnostics, etc.) right after the power-on or reset cancel. *2 : When a cable is to be connected to the USB connector at all times, clamp the cable to prevent a loose connection,

shifting, or disconnection by pulling due to carelessness.

*3 : Operate the RUN/STOP/RESET switche with your fingertips.

Do not use any tool such as a screwdriver because the switch part might be damaged.

On : Off : Normal

Connector used to connect to the USB compatible peripheral devices.

(Connector type B)

Can be connected by the USB dedicated cable.

RUN : Executes sequence program operation.

STOP : Stops sequence program operation. RESET :

For connection of the battery lead wires (When shipped from the factory, the lead wires

are disconnected from the connector to prevent the battery from discharging.)

When the anunciator (F) turns ON

When a battery error has occurred due to the CPU battery voltage drop

Performs hardware reset and operation initialization when an operation

error occurs.

Section 4.4

4.2 Part Names

4 - 4

POWER SUPPLY

MODULE

BASE UNIT

BATTERY

CPU MODULE START-

UP PROCEDURES

CPU MODULE

4.3 Switch Operation after Writing a Program

Programs can be written to the CPU module in either the STOP or RUN status.

(1) When writing a program with the CPU module set to "STOP"

(a) Set the RUN/STOP/RESET switch to STOP.

The "RUN" LED turns Off, and the module is placed in the STOP status. Write a program from GX Developer to the CPU module in the STOP status.

(b) Reset with the RUN/STOP/RESET switch.

The CPU module is reset. ( Section 4.4)

The "RUN" LED turns on, and the CPU module is placed in the RUN status.

(2) When writing a program during RUN

When writing a program during RUN, the operation for the RUN/STOP/RESET switch is not required.

POINT

1. The program modified online during boot operation is written to the program memory.

After making online program change, also write the program to the standard

ROM of the boot source memory. If the program is not written in the standard ROM, the old program will be executed at the next boot operation.

For details of the boot operation, refer to the manual below.

QSCPU User's Manual (Function Explanation, Program Fundamentals)

2. To stop the CPU module, the remote operation of GX Developer can also be used.

In this case, the operation for the RUN/STOP/RESET switch is not required. For details on the remote operation of GX Developer, refer to the following

manual.

GX Developer Version 8 Operating Manual

4 - 5

4.3 Switch Operation after Writing a Program

CPU MODULE

4.4 Reset Operation

For the CPU module, the RUN/STOP/RESET switch of the CPU module is used to switch between the "RUN status" and "STOP status" and to perform "RESET operation". When using the RUN/STOP/RESET switch to reset the CPU module, moving the RUN/ STOP/RESET switch to the reset position will not reset it immediately.

POINT

Perform reset operation with the RUN/STOP/RESET switch as shown in Figure 4.4.

Hold the RUN/STOP/RESET switch in the RESET position until reset processing is complete (the flashing ERR. LED turns off). If you release your hand from the RUN/STOP/RESET switch during reset processing (during rapid flashing of ERR. LED), the switch will return to the STOP position and reset processing cannot be completed.

Start

Hold the RUN/STOP/RESET switch

.......................

in the "RESET" position.

Reset operation is started using the RUN/STOP/RESET switch.

OVERVIEW

SYSTEM

CONFIGURATION

GENERAL

SPECIFICATIONS

STOP

RESET

The ERR. LED flashes several times

Return the RUN/STOP/RESET

switch to the "STOP" position.

RUN

(3 to 4 times) rapidly.

ALIVE

RUN

ERR.

The "ERR. LED" turns off .

ALIVE

RUN

ERR.

RUN/STOP/RESET switch

TEST USER BAT.

flashing

TEST USER BAT.

Off.

.......................

Reset is accepted and reset processing is performed.

Reset is completed.

Reset is canceled.

CPU MODULE

POWER SUPPLY

MODULE

BASE UNIT

STOP

RUN

RESET

Termination , completed , end

RUN/STOP/RESET switch

Figure 4.4 Reset Operation

Releasing your hand from the RUN/STOP/RESET switch returns it to the STOP position.

4.4 Reset Operation

4 - 6

BATTERY

CPU MODULE START-

UP PROCEDURES

CPU MODULE

POINT

Operate the RUN/STOP/RESET switch with your fingertips. Do not use any tool such as a screwdriver because the switch part might be damaged.

4 - 7

4.4 Reset Operation

POWER SUPPLY MODULE

CHAPTER5 POWER SUPPLY MODULE

This section describes the specifications of the power supply modules applicable for the PLC system and how to select the most suitable module.

5.1 Specifications

Table5.1 shows the specifications of the power supply modules.

OVERVIEW

Table5.1 Power supply module specifications

Item

Base loading position QS series power supply module loading slot

Applicable base unit QS034B

Input power supply

Input frequency

Input voltage distortion factor

Max. input apparent power 125VA

Inrush current

Rated output

current

Overcurrent

protection

Overvoltage

protection

Efficiency 70% or more

Allowable momentary power

failure period

Dielectric withstand voltage

Insulation resistance

Noise durability

Operation indication LED indication (Normal: On (green), Error: Off)

Fuse Built-in (Unchangeable by user)

5VDC 6A

5VDC 6.6A or more

5VDC 5.5 to 6.5V

Across inputs/LG and outputs/FG

1780VAC rms/3 cycles (2000 m (6562 ft.))

Across inputs/LG and outputs/FG, across inputs and LG, across outputs and FG 10M

or more by insulation resistance tester

• By noise simulator of 1500Vp-p noise voltage, 1 s noise width and 25 to 60Hz noise

frequency

• Noise voltage IEC61000-4-4, 2kV

QS061P-A1 QS061P-A2

100 to 120VAC

(85 to 132VAC)

Performance Specifications

+10%

-15%

50/60Hz 5%

Within 5% ( Section 5.2)

20A within 8ms

Within 20ms

Across inputs/LG and outputs/FG

2830VAC rms/3 cycles (2000 m (6562 ft.))

200 to 240VAC

(170 to 264VAC)

+10%

-15%

SYSTEM

CONFIGURATION

GENERAL

SPECIFICATIONS

CPU MODULE

POWER SUPPLY

MODULE

BASE UNIT

5.1 Specifications

5 - 1

BATTERY

CPU MODULE START-

UP PROCEDURES

POWER SUPPLY MODULE

Table5.1 Power supply module specifications (Continue)

Item

Application

Rated switching

voltage, current

Minimum switching

load

Response time OFF to ON: 10ms max. ON to OFF: 12ms max.

Life

Contact output section

Surge suppressor No

Fuse No

Terminal screw size M3.5 screw

Applicable wire size

Applicable solderless terminal RAV1.25 to 3.5, RAV2 to 3.5 (0.8mm or less thick)

Applicable tightening torque 0.66 to 0.89N•m

External

dimensions

Weight 0.40kg

H 98mm (3.86inch)

W 55.2mm (2.17inch)

D 115mm (4.53inch)

Electrical : More than 100 thousand times at rated switching voltage, current

QS061P-A1 QS061P-A2

Performance Specifications

contact ( Section 5.3)

ERR.

24VDC, 0.5A

5VDC, 1mA

Mechanical : More than 20 million times

0.75 to 2mm

POINT

*1: Overcurrent protection

The overcurrent protection function shuts off the 5 VDC circuit and stops the system if the current flowing in the circuit exceeds the specified value. The LED of the power supply module is turned off or lights up in dim green when voltage is lowered. If this device is activated, switch the input power supply OFF and eliminate the cause such as insufficient current capacity or short. Then, a few minutes later, switch it ON to restart the system. The initial start for the system takes place when the current value becomes normal.

*2: Overvoltage protection

The overvoltage protection function shuts off the 5 VDC circuit and stops the system if a voltage of 5.5 VDC or above is applied to the circuit. When this device is activated, the power supply module LED is turned OFF. For restart of the system, turn OFF the input power supply, and then turn ON in a few minutes. This allows the system to start up with initial start. If the system doesn't start up and a LED indication remains off, replacement of a power supply module is required.

*3: Allowable momentary power failure period

• An instantaneous power failure lasting less than 20ms will cause AC down to be detected, but operation will continue.

• An instantaneous power failure lasting in excess of 20ms may cause the operation to continue or initial start to take place depending on the power supply load.

*4: Inrush current

When power is switched on again immediately (within 5 seconds) after power-off, an inrush current of more than the specified value (2ms or less) may flow. Reapply power 5 or more seconds after power-off. When selecting a fuse and breaker in the external circuit, take account of the blowout, detection characteristics and above matters.

5 - 2

5.1 Specifications

POWER SUPPLY MODULE

5.2 Precaution when connecting the uninterruptive power supply

Be sure of the following terms when connecting the QS Series CPU Module system to the uninterruptive power supply (abbreviated as UPS hereafter):

OVERVIEW

As for UPS, use the online power system or online interactive system with a voltage distortion rate of 5% or less. For the UPS of the commercial online power system, use Mitsubishi Electric's F Series UPS (serial number P or later) (Ex.: FW-F10-0.3K/0.5K). Do not use any UPS of the commercial online power system other than the F series mentioned above.

SYSTEM

CONFIGURATION

GENERAL

SPECIFICATIONS

CPU MODULE

5.2 Precaution when connecting the uninterruptive power supply

5 - 3

POWER SUPPLY

MODULE

BASE UNIT

BATTERY

CPU MODULE START-

UP PROCEDURES

POWER SUPPLY MODULE

5.3 Names of Parts and Settings

The names of the parts of each power supply module are described below.

QS061P-A1 100 to 120VAC input, 5VDC 6A output QS061P-A2 200 to 240VAC input, 5VDC 6A output

1)7)

QS061P-A1

POWER

Figure 5.1 Power supply module

QS061P-A1

POWER

9),10)

5 - 4

5.3 Names of Parts and Settings

POWER SUPPLY MODULE

Table5.2 Part names

No. Name Application

On (green): Normal (5VDC output, instantaneous power failure within 20ms)

Off : • AC power supply is ON, however, the power supply module is out of

order.

1) "POWER" LED

• Turned ON when the whole system operates normally.

2) ERR. terminal

3) FG terminal

4) LG terminal

5) Terminal screw M3.5 screw

6) Terminal cover Protective cover of the terminal block

7) Module fixing screw

8) Module loading lever Used to load the module to the base unit.

9) Power input terminal Power input terminal for the QS061P-A1 and connected to a 100VAC power supply.

10) Power input terminal Power input terminal for the QS061P-A2 and connected to a 200VAC power supply.

• Turns OFF (opens) when the AC power is not input, a stop error (including a reset)

occurs in the CPU module, or the fuse is blown.

Ground terminal connected to the shielding pattern of the printed-circuit board.

This terminal is functional grounding terminal.

Grounding for the power filter. The potential of the QS061P-A1 and QS061P-A2 ter-

minals are one-half of the input voltage.

This terminal is protective grounding terminal.

Used to fix the module to the base unit.

M3 screw (Tightening torque : 0.36 to 0.48N•m)

(5VDC error, overload, internal circuit failure, fuse blown)

• AC power supply is not ON.

• Power failure (including an instantaneous power failure of 20ms or

more)

OVERVIEW

SYSTEM

CONFIGURATION

GENERAL

SPECIFICATIONS

CPU MODULE

POINT

1. The QS061P-A1 is dedicated for inputting a voltage of 100 VAC. Do not input a voltage of 200 VAC into it or trouble may occur on the QS061P-A1.

Table5.3 Precaution

Power module

type

QS061P-A1 Operates normally.

Power supply module does not

QS061P-A2

2. Ensure that the earth terminals LG and FG are grounded.

3. ERR.

terminal cannot be used as a safety output.

Connect the cable for ERR.

cause trouble.

CPU module cannot be

operated.

100VAC 200VAC

contact of 30m or less in length in a control panel.

Supply power voltage

Power supply module causes

trouble.

Operates normally.

POWER SUPPLY

MODULE

BASE UNIT

BATTERY

5.3 Names of Parts and Settings

5 - 5

CPU MODULE START-

UP PROCEDURES

BASE UNIT

CHAPTER6 BASE UNIT

This section describes the specifications of the base units used in the PLC system.

6.1 Specification

The base unit is a unit to which the CPU module, power supply module and/or intelligent function module are installed.

Table6.1 Base unit specifications

Item

Number of I/O modules installed 4

Possibility of extension Disable

Applicable module QS series modules

5 VDC internal current consumption 0.10A

Mounting hole size

H 98mm (3.86inch)

External dimensions

Weight 0.28kg

Attachment

DIN rail mounting Adapter type Q6DIN2

W 245mm (9.65inch)

D 44.1mm (1.74inch)

Mounting screw M4 14 4 pieces (DIN rail mounting adapter to be sold separately)

M4 screw hole or 4.5 hole (for M4 screw)

Type

QS034B

6 - 1

6.1 Specification

BASE UNIT

6.2 Part Names

The names of the parts of the base unit are described below.

4) 3)

OUT

MODEL

SERIAL

MADE IN JAPAN

POWER

PASSED

BD992C202H01

Figure 6.1 Base unit (QS034B)

OVERVIEW

SYSTEM

CONFIGURATION

I/O3I/O2I/O1I/O0CPU

GENERAL

SPECIFICATIONS

Table6.2 Part Names

No. Name Application

1) Base cover Cover for protecting the printed-circuit board of the base unit

Connector for installing the QS series power supply module, CPU module and

2) Module connector

3) Module fixing screw hole

4) Base mounting hole Hole for mounting this base unit onto the panel of the control panel (for M4 screw)

5) DIN rail adapter mounting hole Hole for mounting DIN rail adapter

intelligent function module.

For the reserved connector where no module is mounted, attach a supplied

connector cover or a blank cover (QG60) to prevent entry of dust.

Screw hole for fixing the module to the base unit. Screw size: M3 12

CPU MODULE

POWER SUPPLY

MODULE

BASE UNIT

6.2 Part Names

6 - 2

BATTERY

CPU MODULE START-

UP PROCEDURES

BATTERY

CHAPTER7 BATTERY

This section describes the specifications of the batteries available for the QS Series CPU Module and how to handle them.

7.1 Battery (Q6BAT)

Batteries (Q6BAT) are installed in the CPU module to retain data of the program memory, and Error•operation history in case of power failure.

7.1.1 Battery Specifications

This section describes the specifications of the battery used for the CPU module.Note1

Table7.1 Battery Specifications

Item

Classification Manganese dioxide lithium primary battery

Initial voltage 3.0V

Nominal current 1800mAh

Storage life Actually 5 years (room temperature)

Total power failure

time

Application Power failure backup for program memory, operation/error history

Remark

1. Refer to Section 11.3.1 for the battery life.

2. For the battery directive in EU member states, refer to Appendix 4.

Type

Q6BAT

Section 11.3.1.

Note1

7 - 1

7.1 Battery (Q6BAT)

7.1.1 Battery Specifications

BAT.

BATTERY

7.1.2 Installation of Battery

The battery for the CPU module is shipped with its connector disconnected. Connect the connector as follows. Refer to Section 11.3 for the service life of the battery and how to replace the battery.

OVERVIEW

Open the CPU module front cover.

Confirm that the battery is loaded correctly.

Insert the battery connector into the connector pin on the case. Be sure that the insertion direction is correct.

Completed

Figure 7.1 Q6BAT battery setting procedure

Connector

CPU module

SYSTEM

CONFIGURATION

STOP

RUN

RESET

GENERAL

SPECIFICATIONS

CPU MODULE

7.1 Battery (Q6BAT)

7.1.2 Installation of Battery

7 - 2

POWER SUPPLY

MODULE

BASE UNIT

BATTERY

CPU MODULE START-

UP PROCEDURES

CPU MODULE START-UP PROCEDURES

CHAPTER8 CPU MODULE START-UP PROCEDURES

This chapter describes the procedure for starting up the CPU module. It is assumed that programs and parameters have been created separately.

8.1 Procedure before Operating in SAFETY MODE

This section describes the procedure before operating the CPU module in SAFETY MODE. The default operation mode of the CPU module is TEST MODE. Switch the mode to SAFETY MODE to operate the CPU module.

Start

Installing a base unit

Install a base unit to a panel.

Installing modules

Install modules required for the system configuration to the base unit.

Fixing modules by screws

Fix the modules to the base unit with screws to prevent the displacement by vibrations or other causes.

Wiring

1) Wire the power supply to the power supply module.

2) Install wiring between the CC-Link Safety master module and the CC-Link Safety remote I/O module.

3) Wire external device(s) to the CC-Link Safety remote I/O module.

4) Install wiring between network modules.

Making initial settings of modules

1) Set the RUN/STOP/RESET switch of the CPU module to the STOP position. (Set the CPU module to stop status.)

2) Make switch settings for the MELSECNET/H module.

(To the next page)

• • • CHAPTER 10

• • • CHAPTER 2, CHAPTER 10

• • • CHAPTER 10

• • • CHAPTER 4

MELSECNET/H Networ

System Reference Man

(PLC to PLC network)

8 - 1

8.1 Procedure before Operating in SAFETY MODE

CPU MODULE START-UP PROCEDURES

(Continued from the previous page)

Installing a battery

Install a battery to the CPU module.

Powering ON the power supply module

Confirm the following items of the safety PLC system, and then turn on the power supply. Wiring of the power supply Power supply voltage Operating status of the CPU module Stop status (The RUN/STOP/RESET switch is in the STOP position.)

Confirming the CPU module LEDs

Confirm that the "ALIVE" LED and "TEST" LED of the CPU module are on. (Confirm that the CPU module is in TEST MODE.)

Connecting a personal computer in which GX Developer is installed

1) Start up GX Developer on the personal computer in which GX Developer is installed.

2) Connect the personal computer with GX Developer installed, to the CPU module.

Initializing the PLC memory of the CPU module

Initialize the PLC memory of the CPU module with GX Developer.

Registering the CPU access password with the CPU module

Setting clock data and clearing history data of the CPU module

When the safety CPU module is operated for the first time after purchase, take the following actions for the CPU module with GX Developer. Set the clock with "Clock setup". Clear the error history of the CPU module with "PLC diagnostics".

Writing the parameters and programs to the CPU module

Write the parameters and user programs created by GX Developer to the CPU module.

• • • CHAPTER 7

• • • CHAPTER 4, CHAPTER 5, CHAPTER 10

• • • CHAPTER 4

• • • GX Developer Version 8

Operating Manual

• • • GX Developer Version 8

Operating Manual

(Safety PLC)

• • • GX Developer Version 8

Operating Manual

(Safety PLC)

• • • GX Developer Version 8

Operating Manual

GX Developer Version 8

Operating Manual

(Safety PLC)

• • • GX Developer Version 8

Operating Manual

OVERVIEW

SYSTEM

CONFIGURATION

GENERAL

SPECIFICATIONS

CPU MODULE

POWER SUPPLY

MODULE

Restarting the system

Turn off and then turn on the system power supply, or reset the CPU module.

Running the CPU module

Set the RUN/STOP/RESET switch of the CPU module to the RUN position. Confirm that the "ALIVE" LED, "RUN" LED, and "TEST" LED of the CPU module are on.

Checking the user program operation

Check the user program operation, cables, and inputs/outputs. When the "ERR." LED of the CPU module is on or flashing, identify the error cause by the diagnostics* When the error is related to the parameters or programs, correct them.

of GX Developer to eliminate the error cause.

(To the next page)

*2: The following types of diagnostics are available. PLC diagnostics

Ethernet diagnostics

CC IE Control diagnostics

MELSECNET diagnostics CC-Link / CC-Link/LT diagnostics System monitor

8.1 Procedure before Operating in SAFETY MODE

• • • CHAPTER 4

8 - 2

BASE UNIT

BATTERY

CPU MODULE START-

UP PROCEDURES

CPU MODULE START-UP PROCEDURES

(Continued from the previous page)

Stopping the CPU module

Set the RUN/STOP/RESET switch of the CPU module to the STOP position.

Switching to SAFETY MODE

Switch the mode from TEST MODE to SAFETY MODE by selecting the menu option, "Switch safety CPU operation mode", in GX Developer.

Confirming the CPU module LEDs

After the operation mode has been switched from TEST MODE to SAFETY MODE using GX Developer, confirm that the "TEST" LED of the CPU module is flashing while the "ALIVE" LED is on.

Restarting the system

Turn the system power supply OFF and then ON, or perform the reset operation on the CPU module.

Running the CPU module

Set the RUN/STOP/RESET switch of the CPU module to the RUN position. Confirm that the "ALIVE" LED and "RUN" LED of the CPU module are on, and the "TEST" LED is off.

YES

Correct the program?

• • • CHAPTER 4

• • • GX Developer Version 8

Operating Manual

(Safety PLC)

• • • CHAPTER 4

End

Stopping the CPU module

Set the RUN/STOP/RESET switch of the CPU module to the STOP position.

Switching to TEST MODE

Switch the mode from SAFETY MODE to TEST MODE by selecting the menu option, "Switch safety CPU operation mode", in GX Developer.

Confirming the CPU module LEDs

After the operation mode has been switched from SAFETY MODE to TEST MODE using GX Developer, confirm that both the "TEST" LED and "ALIVE" LED of the CPU module are on.

Correcting the program

Correct the program with GX Developer.

• • • CHAPTER 4

• • •

Operating Manual

(Safety PLC)

• • • CHAPTER 4

• • •

Operating Manual

GX Developer Version 8

8 - 3

8.1 Procedure before Operating in SAFETY MODE

EMC AND LOW VOLTAGE DIRECTIVES

CHAPTER9 EMC AND LOW VOLTAGE DIRECTIVES

For the products sold in European countries, the conformance to the EMC Directive, which is one of the European directives, has been a legal obligation since 1996. Also, conformance to the Low Voltage Directive, another European Directive, has been a legal obligation since 1997. Manufacturers who recognize their products must conform to the EMC and Low Voltage Directives are required to declare that their products conform to these Directives and put a "CE mark" on their products.

9.1 Requirements for Conformance to EMC Directive

The EMC Directive specifies that products placed on the market must "be so constructed that they do not cause excessive electromagnetic interference (emissions) and are not unduly affected by electromagnetic interference (immunity)". The applicable products are requested to meet these requirements. The Section 9.1.1 through Section 9.1.5 summarize the precautions on conformance to the EMC Directive of the machinery constructed using the MELSEC-QS series PLCs. The details of these precautions has been prepared based on the control requirements and the applicable standards control. However, we will not assure that the overall machinery manufactured according to these details conforms to the above-mentioned directives. The method of conformance to the EMC Directive and the judgment on whether or not the machinery conforms to the EMC Directive must be determined finally by the manufacturer of the machinery.

EMC AND LOW

VOLTAGE

LOADING AND

MAINTENANCE AND

DIRECTIVES

INSTALLATION

INSPECTION

TROUBLESHOOTING APPENDICES INDEX

9.1.1 Standards relevant to the EMC Directive

The standards relevant to the EMC Directive are listed in Table9.1.

Table9.1 Standards relevant to the EMC Directive

Specification Test Item Test Details Standard Value

30M-230MHz QP:

40dB V/m (10m (32.81 ft.) in

: 79dB

: 66dB

: 73dB

: 60dB

EN61131-2 :

2003

EN55011(CISPR11)

Radiated emission

EN55011(CISPR11)

Conducted emission

Radio waves from the product

are measured.

Noise from the product to the

power line is measured.

measurement range)

230M-1000MHz QP:

47dB V/m(10m (32.81 ft.) in

measurement range)

150k-500kHz QP

Mean

500k-30MHz QP

Mean

9.1 Requirements for Conformance to EMC Directive

9.1.1 Standards relevant to the EMC Directive

9 - 1

EMC AND LOW VOLTAGE DIRECTIVES

Table9.1 Standards relevant to the EMC Directive (Continue)

Specification Test Item Test Details Standard Value

EN61000-4-2

Electrostatic discharge

immunity

EN61000-4-3

Radiated electromagnetic

field immunity

EN61000-4-8

Power frequency

magnetic field immunity

EN61000-4-4

Electrical fast transient/

burst immunity

EN61131-2 :

2003

EN61000-4-5

Surge immunity

EN61000-4-6

Conducted disturbances

immunity

*1: QP : Quasi-peak value, Mean : Average value

*2: The PLC is an open type device (device installed to another device) and must be installed in a conductive control panel.

The tests for the corresponding items were performed while the PLC was installed inside a control panel.

Immunity test in which

electrostatic is applied to the

cabinet of the equipment.

Immunity test in which electric

fields are irradiated to the

product.

Immunity test in which the

product is installed in the

magnetic field of the induction

coil.

Immunity test in which burst

noise is applied to the power line

and signal line.

Immunity test in which lightning

surge is applied to the power line

and signal line.

Immunity test in which high

frequency noise is applied to the

power line and signal line.

8kV Air discharge

4kV Contact discharge

1.4GHz-2.0GHz, 80-1000MHz, 10V/m,

80%AM modulation 1kHz

50Hz/60Hz, 30A/m

AC power line: 2kV

DC power line: 2kV

DC I/O, analog, communication line: 1kV

AC power line:

Common mode 2kV, differential

mode 1kV

DC power line:

Common mode 1kV, differential

mode 0.5kV

DC I/O, analog, communication (shielded):

Common mode 1kV

DC I/O, analog (unshielded):

Common mode 0.5kV, differential

mode 0.5kV

Communication (unshielded):

1kV

0.15-80MHz, 80%AM modulation 1kHz,

3Vrms

9 - 2

9.1 Requirements for Conformance to EMC Directive

9.1.1 Standards relevant to the EMC Directive

EMC AND LOW VOLTAGE DIRECTIVES

9.1.2 Installation instructions for EMC Directive

The PLC is open equipment and must be installed within a control panel for use.* This not only ensures safety but also ensures effective shielding of PLC-generated electromagnetic noise.

* : CC-Link Safety remote station should be used having the control panel installed.

(1) Control panel

• Use a conductive control panel.

• When attaching the control panel's top plate or base plate, mask painting and weld so that good surface contact can be made between the panel and plate.

• To ensure good electrical contact with the control panel, mask the paint on the installation bolts of the inner plate in the control panel so that contact between surfaces can be ensured over the widest possible area.

• Earth the control panel with a thick wire so that a low impedance connection to ground can be ensured even at high frequencies.

• Holes made in the control panel must be 10 cm (3.94 inch) diameter or less. If the holes are 10 cm (3.94 inch) or larger, radio frequency noise may be emitted. In addition, because radio waves leak through a clearance between the control panel door and the main unit, reduce the clearance as much as practicable. The leakage of radio waves can be suppressed by the direct application of an EMI gasket on the paint surface.

EMC AND LOW

VOLTAGE

LOADING AND

MAINTENANCE AND

DIRECTIVES

INSTALLATION

INSPECTION

Our tests have been carried out on a panel having the damping characteristics of 37 dB max. and 30 dB mean (measured by 3 m method with 30 to 300 MHz).

(2) Connection of power and earth wires

Earthing and power supply wires for the PLC system must be connected as described below.

• Provide an earthing point near the power supply module. Earth the power supply's LG and FG terminals (LG : Line Ground, FG : Frame Ground) with the thickest and shortest wire possible. (The wire length must be 30 cm (11.81 inch) or shorter.) The LG and FG terminals function is to pass the noise generated in the PLC system to the ground, so an impedance that is as low as possible must be ensured. As the wires are used to relieve the noise, the wire itself carries a large noise content and thus short wiring means that the wire is prevented from acting as an antenna.

• The earth wire led from the earthing point must be twisted with the power supply wires. By twisting with the earthing wire, noise flowing from the power supply wires can be relieved to the earthing. However, if a filter is installed on the power supply wires, the wires and the earthing wire may not need to be twisted.

TROUBLESHOOTING APPENDICES INDEX

9.1 Requirements for Conformance to EMC Directive

9.1.2 Installation instructions for EMC Directive

9 - 3

EMC AND LOW VOLTAGE DIRECTIVES

9.1.3 Cables

The cables pulled out from the control panel contain a high frequency noise component. On the outside of the control panel, therefore, they serve as antennas to emit noise. To prevent noise emission, use shielded cables when pulling out the cables which are connected to CC-Link Safety master module, MELSECNET/H module, Ethernet module, and CC-Link Safety remote I/O module and using them outside of the control panel. The use of shielded cables also increases noise immunity. For signal lines (including common line) of CC-Link Safety master module, MELSECNET/ H module, Ethernet module, and CC-Link Safety remote I/O module, the noise immunity satisfies the standard value on the condition that the shielded cables are used for grounding. If shielded cables are not used or not grounded correctly, the noise immunity does not meet the specified requirements.

(1) Shield grounding processing of shielded cables

• Provide a grounding point on the shielded cable as near the module as possible so that the wiring between the module and grounding point is not induced electromagnetically by the other parts of wiring on the cable.

• Take appropriate measures so that the exposed shield part of the shielded cable, where the cable jacket was partly removed, is grounded to the control panel on the wildest contact surface. A clamp may also be used as shown in Figure 9.2. In this case, however, a mask painting is required for the inner wall of the control panel which comes into contact with the clamp.

Screw

Shield part

Mask painting

Figure 9.1 Part to be exposed Figure 9.2 Shield grounding (Good example)

Note) If a wire is soldered onto the shield part of the shielded cable for grounding

as shown below, the high-frequency impedance rises, resulting in a loss of shield effect.

Shield cable Wire

Solderless terminal

Figure 9.3 Shield grounding (Bad example)

Clamp

Shield cable

9 - 4

9.1 Requirements for Conformance to EMC Directive

9.1.3 Cables

EMC AND LOW VOLTAGE DIRECTIVES

(2) MELSECNET/H module

Be sure to use double-shielded coaxial cables (MITSUBISHI CABLE INDUSTRIES, LTD.: 5C-2V-CCY) for the coaxial cables of MELSECNET/H module. Radiated noise in the range of 30HMz or higher can be suppressed by using double-shielded coaxial cables. Ground the double-shielded coaxial cable by connecting its outer shield to the ground.

EMC AND LOW

VOLTAGE

DIRECTIVES

Shield

Figure 9.4 Double-shielded coaxial cable grounding

Refer to (1) for the shield grounding processing.

Earth here

(3) Ethernet module

Precautions for using AUI cables, twisted pair cables, and coaxial cables are described below.

• Be sure to ground the AUI cables the AUI cable is of the shielded type, ground the exposed shield section of the cable, where the cable jacket was partly removed as shown in Figure 9.5, on the wildest contact surface.

AUI cable

Shield

Figure 9.5 AUI cable grounding

Refer to (1) for the shield grounding processing.

* 1 : Make sure to install a ferrite core for the cable.

The ZCAT2032 ferrite core manufactured by TDK is recommended.

connected to the 10BASE5 connectors. Since

LOADING AND

MAINTENANCE AND

INSTALLATION

INSPECTION

TROUBLESHOOTING APPENDICES INDEX

Use shielded twisted pair cables for the twisted pair cables connected to the 10BASET/100BASE-TX connectors. Ground the exposed shield section of the shielded twisted pair cable, where the cable jacket was partly removed as shown in Figure 9.6, on the wildest contact surface.

Shielded twisted pair cable

Shield

Figure 9.6 Shielded twisted pair cable groundng

Refer to (1) for the shield grounding processing.

9.1 Requirements for Conformance to EMC Directive

9.1.3 Cables

9 - 5

EMC AND LOW VOLTAGE DIRECTIVES

Be sure to use double-shielded coaxial cables for the coaxial cables*2 connected to the 10BASE2 connectors. Ground the double-shielded coaxial cable by connecting its outer shield to the ground

Shield

Figure 9.7 SDouble-shielded coaxial cable grounding

Refer to (1) for the shield grounding processing.

* 1 : Make sure to install a ferrite core for the cable.

The ZCAT2032 ferrite core manufactured by TDK is recommended.

(4) I/O signal lines and other communication cables

If the I/O signal lines (including common line) and other communication cables (such as CC-Link Safety) are pulled out from the control panel, be sure to ground the shieldsections of the cables as described in (1).

9.1.4 Power Supply Module

Always ground the LG and FG terminals after short-circuiting them.

Ground here

9 - 6

9.1 Requirements for Conformance to EMC Directive

9.1.4 Power Supply Module

EMC AND LOW VOLTAGE DIRECTIVES

9.1.5 Others

(1) Ferrite core

A ferrite core has the effect of reducing conduction noise in around 10MHz band and radiated noise in the 30MHz to 100MHz band. It is recommended to fit ferrite cores if shielded cables pulled out of the panel do not provide sufficient shielding effects or if the emission of conduction noise from the power supply line has to be suppressed. It is also recommended to fit a ferrite core to the USB cable which connects the CPU and the personal computer as measures against noise. Regarding the number of winding to the ferrite core, the more the better. The two turns or more is recommended as the number of winding.

EMC AND LOW

VOLTAGE

LOADING AND

MAINTENANCE AND

DIRECTIVES

INSTALLATION

INSPECTION

Figure 9.8 For number of winding is two turns or more

Note that the ferrite cores should be fitted to the cables in the position immediately before they are pulled out of the panel. If the fitting position is improper, the ferrite will not produce any effect.

TROUBLESHOOTING APPENDICES INDEX

9.1 Requirements for Conformance to EMC Directive

9.1.5 Others

9 - 7

EMC AND LOW VOLTAGE DIRECTIVES

(2) Noise filter (power supply line filter)

A noise filter is a component which has an effect on conducted noise. It is not required to fit the noise filter to the power supply line, but fitting it can further suppress noise. (The noise filter has the effect of reducing conducted noise of 10 MHz or less.)

The precautions required when installing a noise filter are described below.

• Do not bundle the wires on the input side and output side of the noise filter. When bundled, the output side noise will be induced into the input side wires from which the noise was filtered.

Input side

(power supply side)

Induction

Filter

Output side

(device side)

The noise will be included when the input and output wires are bundled.

Figure 9.9 Precautions on noise filter

• Earth the noise filter earthing terminal to the control cabinet with the shortest wire possible (approx. 10 cm (3.94 inch)).

Remark

Table9.2 Noise filer specifications

Noise Filter Model Name FN343-3/01 FN660-6/06 ZHC2203-11

Manufacturer SCHAFFNER SCHAFFNER TDK

Rated current 3A 6A 3A

Rated voltage 250V

Input side

(power supply side)

Filter

Output side

(device side)

Separate and lay the input and output wires.

9 - 8

9.1 Requirements for Conformance to EMC Directive

9.1.5 Others

EMC AND LOW VOLTAGE DIRECTIVES

9.2 Requirement to Conform to the Low Voltage Directive

The Low Voltage Directive requires each device that operates with the power supply ranging from 50 to 1000VAC and 75 to 1500VDC to satisfy the safety requirements. In Section 9.2.1 to Section 9.2.6, cautions on installation and wiring of the MELSEC-QS series PLC to conform to the Low Voltage Directive are described. These descriptions are based on the requirements and standards of the regulation, however, it does not guarantee that the entire machinery manufactured based on the descriptions conforms to the above-mentioned directive. The method and judgment for the conformity to the low voltage directive must be left to the manufacturer's own discretion.

9.2.1 Standard applied for MELSEC-QS series PLC

The standard applied for MELSEC-QS series PLC is EN61131-2 safety of devices used in measurement rooms, control rooms, or laboratories.

The MELSEC-QS series PLC modules which operate at the rated voltage of 50VAC/ 75VDC or above are also developed to conform to the above standard. The modules which operate at the rated voltage of less than 50VAC/75VDC are out of the Low Voltage Directive application range. For products with the CE mark, refer to the "Standard Compliance" menu of the MELFANSweb homepage.

EMC AND LOW

VOLTAGE

LOADING AND

MAINTENANCE AND

DIRECTIVES

INSTALLATION

INSPECTION

9.2.2 MELSEC-QS series PLC selection

(1) Power supply module

There are dangerous voltages (voltages higher than 42.4V peak) inside the power supply modules of the 100/200VAC rated input voltages. Therefore, the CE marked models are enhanced in insulation internally between the primary and secondary.

(2) CPU module, base unit

Using 5VDC circuits inside, the above modules are out of the Low Voltage Directive application range.

(3) CC-Link Safety master module, CC-Link IE controller network module,

MELSECNET/H module, Ethernet module

These modules are out of the scope of the Low Voltage Directive because the rated voltage is 24VDC or less.

TROUBLESHOOTING APPENDICES INDEX

9.2 Requirement to Conform to the Low Voltage Directive

9.2.1 Standard applied for MELSEC-QS series PLC

9 - 9

EMC AND LOW VOLTAGE DIRECTIVES

9.2.3 Power supply

The insulation specification of the power supply module was designed assuming installation category II. Be sure to use the installation category II power supply to the PLC. The installation category indicates the durability level against surge voltage generated by a thunderbolt. Category I has the lowest durability; category IV has the highest durability.

Category IV Category III Category II Category I

Figure 9.10 Installation category for power supply module

Category II indicates a power supply whose voltage has been reduced by two or more levels of isolating transformers from the public power distribution.

9.2.4 Control panel

Because the PLC is an open device (a device designed to be stored within another module), be sure to use it after storing in the control panel.*

* : Also, each network remote station needs to be installed inside the control panel.

(1) Electrical shock prevention

The control panel must be handled as shown below to protect a person who does not have adequate knowledge of electricity from an electric shock.

• Lock the control panel so that only those who are trained and have acquired enough knowledge of electric facilities can open the control panel.

• The control panel must have a structure which automatically stops the power supply when the box is opened.

• For electric shock protection, use IP20 or greater control panel.

9 - 10

9.2 Requirement to Conform to the Low Voltage Directive

9.2.3 Power supply

EMC AND LOW VOLTAGE DIRECTIVES

(2) Dustproof and waterproof features

The control panel also has the dustproof and waterproof functions. Insufficient dustproof and waterproof features lower the insulation withstand voltage, resulting in insulation destruction. The insulation in our PLC is designed to cope with the pollution level 2, so use in an environment with pollustion level 2 or below.

Pollution level 1 : An environment where the air is dry and conductive dust

does not exist.

Pollution level 2 : An environment where conductive dust

does not usually exist, but occasional temporary conductivity occurs due to the accumulated dust. Generally, this is the level for inside the control box equivalent to IP54 in a control room or on the floor of a typical factory.

Pollution level 3 : An environment where conductive dust exits and

conductivity may be generated due to the accumulated dust. An environment for a typical factory floor.

Pollution level 4 : Continuous conductivity may occur due to rain, snow, etc.

An outdoor environment.

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As shown above, the PLC can realize the pollution level 2 when stored in a control panel equivalent to IP54.

TROUBLESHOOTING APPENDICES INDEX

9.2 Requirement to Conform to the Low Voltage Directive

9.2.4 Control panel

9 - 11

EMC AND LOW VOLTAGE DIRECTIVES

9.2.5 Grounding

There are the following two different grounding terminals. Use either grounding terminal in an earthed status.

Protective grounding : Maintains the electrical safety of the PLC and improves the

noise resistance.

Functional grounding : Improves the noise resistance.

9.2.6 External wiring

(1) 24VDC external power supply

This power supply must include a reinforced insulation for 24VDC circuit to prevent dangerous voltage for CC-Link Safety remote I/O module.

(2) External devices

When a device with a hazardous voltage circuit is externally connected to the PLC, use the device whose interface circuit section to the PLC has the reinforced insulation against the hazardous voltage circuit.

(3) Reinforced insulation

The reinforced insulation covers the withstand voltages shown in Table9.3.

Table9.3 Reinforced Insulation Withstand Voltage

(Installation Category II, source : IEC664)

Rated voltage of hazardous

voltage area

150VAC or below 2500V

300VAC or below 4000V

Surge withstand voltage

(1.2/50 s)

9 - 12

9.2 Requirement to Conform to the Low Voltage Directive

9.2.5 Grounding

LOADING AND INSTALLATION

CHAPTER10 LOADING AND INSTALLATION

In order to increase the reliability of the system and exploit the maximum performance of its functions, this section describes the methods and precautions for the mounting and installation of the system.

EMC AND LOW

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DANGER

When a safety PLC detects an error in an external power supply or a fail-

ure in PLC main module, it turns off all the outputs. Create an external circuit to securely stop the power of hazard by turning off the outputs.Incorrect configuration may result in an accident.

Create short current protection for a safety relay, and a protection circuit

such as a fuse, and breaker, outside a safety PLC.

When data/program change, or status control is performed from a PC to

a running safety PLC, create an interlock circuit outside the sequence program and safety PLC to ensure that the whole system always operates safely. For the operations to a safety PLC, pay full attention to safety by reading the relevant manuals carefully, and establishing the operating procedure. Furthermore, for the online operations performed from a PC to a safety CPU module, the corrective actions of the whole system should be predetermined in case that a communication error occurs due to a cable connection fault, etc.

All output signals from a safety CPU module to the CC-Link Safety sys-

tem master module are prohibited to use. These signals can be found in the CC-Link Safety System Master Module User's Manual. Do not turn ON or OFF these signals by sequence program, since turning ON/OFF these output signals of the PLC system may cause malfunctions and safety operation cannot be guaranteed.

When a safety remote I/O module has detected a CC-Link Safety error, it

turns off all the outputs. Note that the outputs in a sequence program are not automatically turned off. If a CC-Link Safety error has been detected, create a sequence program that turns off the outputs in the program. If the CC-Link Safety is restored with the outputs on, it may suddenly operate and result in an accident.

LOADING AND

MAINTENANCE AND

INSTALLATION

INSPECTION

TROUBLESHOOTING APPENDICES INDEX

To inhibit restart without manual operation after safety functions was

performed and outputs were turned OFF, create an interlock program which uses a reset button for restart.

10 - 1

LOADING AND INSTALLATION

CAUTION

Do not bunch the wires of external devices or communication cables

together with the main circuit or power lines, or install them close to each other.They should be installed 100 mm (3.94 inch) or more from each other.Not doing so could result in noise that would cause erroneous operation.

10 - 2

10.1 Calculating Heat Generation of PLC

LOADING AND INSTALLATION

The ambient temperature inside the panel storing the PLC must be suppressed to an

ambient temperature of 55 or less, which is specified for the PLC. For the design of a heat releasing panel, it is necessary to know the average power consumption (heating value) of the devices and instruments stored inside. Here the method of obtaining the average power consumption of the PLC system is described. From the power consumption, calculate a rise in ambient temperature inside the panel.

How to calculate average power consumption

The power consuming parts of the PLC are roughly classified into six blocks as shown below.

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(1) Power consumption of power supply module

The power conversion efficiency of the power supply module is approx. 70 %, while 30 % of the output power is consumed as heat. As a result, 3/7 of the output power is the power consumption. Therefore the calculation formula is as follows.

PW =

×(I5v×5) (W)

: Current consumption of logic 5 VDC circuit of each module

(2) Total power consumption for 5VDC logic circuits of all modules

(including CPU module)

The power consumption of the 5 VDC output circuit section of the power supply module is the power consumption of each module (including the current consumption of the base unit).

= I5V5 (W)

The total of the power consumption values calculated for each block becomes the power consumption of the overall sequencer system.

W = WPW+W

MAINTENANCE AND

INSPECTION

TROUBLESHOOTING APPENDICES INDEX

From this overall power consumption (W), calculate the heating value and a rise in ambient temperature inside the panel. The outline of the calculation formula for a rise in ambient temperature inside the panel is shown below.

W : Power consumption of overall sequencer system (value obtained above) A : Surface area inside the panel

U : When the ambient temperature inside the panel is uniformed by a fan........ 6

When air inside the panel is not circulated ................................................... 4

10.1 Calculating Heat Generation of PLC

10 - 3

LOADING AND INSTALLATION

POINT

If the temperature inside the panel has exceeded the specified range, it is recommended to install a heat exchanger to the panel to lower the temperature. If a normal ventilating fan is used, dust will be sucked into the PLC together with the external air, and it may affect the performance of the PLC.

(3) Example of calculation of average power consumption

(a) System configuration

QS061P-A1 QS001CPU

QS034

QS0J61BT12

Figure 10.1 System configuration

(b) 5 VDC current consumption of each module

QS001CPU : 0.43(A) QS0J61BT12 : 0.46(A) QS034B : 0.10(A)

PW = 3/7 (0.43 + 0.46 + 0.10) 5 = 2.12(W)

(d) Total power consumption for 5 VDC logic circuits of all module

5V = (0.43 + 0.46 + 0.10) 5 = 4.95(W)

(e) Power consumption of overall system

W = 2.12 + 4.95 = 7.07(W)

10 - 4

10.1 Calculating Heat Generation of PLC

10.2 Module Installation

LOADING AND INSTALLATION

10.2.1 Precaution on installation

CAUTION

Use a safety PLC in the environment that meets the general specifica-

tions described in this manual. Using this PLC in an environment outside the range of the general specifications could result in electric shock, fire, erroneous operation, and damage to or deterioration of the product

While pressing the installation lever located at the bottom of module,

insert the module fixing tab into the fixing hole in the base unit until it stops. Then, securely mount the module with the fixing hole as a supporting point.Incorrect loading of the module can cause a failure or drop. Secure the module to the base unit with screws.Tighten the screw in the specified torque range.If the screws are too loose, it may cause a drop of the screw or module. Over tightening may cause a drop due to the damage of the screw or module.

Completely turn off the externally supplied power used in the system

before mounting or removingthe module. Not doing so could result in damage to the product.

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TROUBLESHOOTING APPENDICES INDEX

Do not directly touch the module's conductive parts or electronic compo-

nents. Doing so may cause malfunctions or a failure.

10.2 Module Installation

10.2.1 Precaution on installation

10 - 5

LOADING AND INSTALLATION

This section gives instructions for handling the CPU, and power supply modules, base unit and so on.

• Do not drop the module case and main module or subject them to strong impact.

• Do not remove modules' printed circuit boards from the enclosure in order to avoid changes in operation.

• Tighten the screws such as module fixing screws within the following ranges.

Location of Screw Tightening Torque Range

Module fixing screw (M3 12 screw)

Power supply module terminal screw (M3.5 screw) 0.66 to 0.89N•m

* 1 The module can be easily fixed onto the base unit using the hook at the top of the module.

However, it is recommended to secure the module with the module fixing screw if the module is subject to significant vibration.

• Be sure to install a power supply module in the power supply installation slot of QS034B.

Install a base unit (by screwing) in the following procedure.

Table10.1 Tightening torque range

0.36 to 0.48N•m

1) Fit the two base unit top mounting screws into the enclosure.

Panel

Figure 10.2 Install a base unit

2) Place the right-hand side notch of the base unit onto the right-hand side screw.

Panel

Figure 10.3 Install a base unit

3) Place the left-hand side pear-shaped hole onto the left-hand side screw.

10 - 6

Panel

Figure 10.4 Install a base unit

10.2 Module Installation

10.2.1 Precaution on installation

LOADING AND INSTALLATION

4) Fit the mounting screws into the holes at the bottom of the base unit, and then retighten the 4 mounting screws.

Note1 : Install the base unit to a panel, with no module loaded in the right-end

slot. Remove the base unit after unloading the module from the right-end slot.

Note the following points when mounting a DIN rail. Mounting a DIN rail needs special adaptors (optional), which are to be user-prepared.

(a) Applicable adaptor types

For QS034B : Q6DIN2

Table10.2 Parts included with dinrail mounting adaptors included parts

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DIN rail mounting

adaptors

Q6DIN2 23222

Adaptor(Large) Adaptor(small)

(b) Adaptor installation method

Quantity of included parts

Mounting screw

(M5 10)

Square washer Stopper

MAINTENANCE AND

The way to install the adaptors for mounting a DIN rail to the base unit is given in Figure 10.5.

Base unit rear

Place the hook of the adaptor (small) in the lower hole.

Push the top of the adaptor (small) far enough until it "clicks".

INSPECTION

TROUBLESHOOTING APPENDICES INDEX

Insert the adaptor (large) into the grooves of the base unit from below.

Push the bottom of the adaptor (large) far enough until it "clicks".

Figure 10.5 Adaptor installation method

10.2.1 Precaution on installation

10.2 Module Installation

10 - 7

LOADING AND INSTALLATION

TH35-7.5Fe TH35-7.5AI TH35-15Fe

(d) DIN rail mounting screw intervals

When using either the TH35-7.5Fe or TH35-7.5Al DIN rail, rail mounting screws should be inserted in 200 mm (7.88 inch) interrals or less in order to ensure that the rail has sufficient strength.

DIN rail

35mm (1.38 inch)

PPP

Figure 10.6 DIN rail mounting screw intervals

DIN rail mounting screw

(obtained by user)

P=200mm (7.88 inch) or less

When installing the DIN rail in a large vibration and/or shock prone environment, insert the mounting screws in 200mm interrals or less by the following method show below.

Screw the DIN rail in two places using the mounting screws and square washers included with the adaptors in ‘Position A’ (bottom of base unit).

B *3

DIN rail

35mm

Mounting screws

A *2B *3

(included with adaptors) Square washers necessary *1

Mounting screws (obtained by user)

No square washers

10 - 8

Stopper

* 1

Square washer

Mountiong screws

(M5 10)

* 2: Screw the DIN rail to a control panel using the mounting screws and square washers included

* 3: Screw the DIN rail with mounting screws(obtained by user) in ‘Position B’ (Where the base unit is

10.2 Module Installation

10.2.1 Precaution on installation

DIN rail

Side view A

with the adaptors in ‘Position A’ (bottom of base unit).

not installed). In this method the supplied mounting screws and square washeres are not used.

Stopper

Figure 10.7 DIN rail mounting screw intervals

Figure 10.8 Square washer

P=200mm (7.88 inch) or less

square washer

DIN railMountiong screws

Mounting side

(e.g. Control panel)

Side view A

LOADING AND INSTALLATION

POINT

(1) Use only one washer for each mounting screw. Use only the square washers

supplied with the adaptors. If two or more washers are used together for one mounting screw, the screw may interfere with the base unit.

(2) Make sure to align the square washer sides with the DIN rail.

DIN railsquare washer DIN railsquare washer

Figure 10.9 Precautions when mounting a square washer

(3) Use the DIN rail that is compatible with M5 size screws.

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TROUBLESHOOTING APPENDICES INDEX

10.2 Module Installation

10.2.1 Precaution on installation

10 - 9

LOADING AND INSTALLATION

(e) Stopper mounting

When using the DIN rail in a large vibration and/or shock prone environment, install the base unit using the stoppers supplied with the DIN rail mounting adaptors indicated in (a).

Loosen the screw at the top of the stopper. (2 stoppers)

Hitch the lower hook of the stopper to the bottom of the DIN rail. Install the stopper with the arrowhead side facing up.

Hitch the upper hook of the stopper

3) to the top of the DIN rail.

Slide the stopper to the end of the

base unit so that they are fully in contact.

Tighten the screw of the stopper with a screwdriver. (Tightening torque 1.00 to 1.35N m)

Stopper

Hook

DIN rail

Stopper

Hitch hook to top of DIN rail

2) Hitch hook to bottom

of DIN rail

(Left side)

Make sure that the left and right stoppers are fixed securely to the DIN rail.

Complete

Figure 10.10 Fixture mounting procedure

Stopper

(Right side)

Stopper Stopper

DIN rail

10 - 10

10.2 Module Installation

10.2.1 Precaution on installation

LOADING AND INSTALLATION

POINT

When stoppers are used, the dimension of stoppers need to be considered in the unit installation dimensions. Refer to a CPU user’s manual for the base unit dimensions (W).

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DIRECTIVES

Stopper Stopper

35(1.38)

DIN rail

(f) Dimensions when DIN rail is attached (Side view).

DIN rail depth (D) TH35-7.5Fe, TH35-7.5Al:7.5 (0.30) TH35-15Fe:15 (0.59)

DIN rail adaptor

Base unit

Base unit width : W

W+18(0.71)

Figure 10.11 Base unit external dimensions (Front view)

Board side

Power supply module

(0.20)

7.5D

(0.30)

Base unit

DIN rail center

Unit: mm (inch)

49 49

(1.93)

98(3.86)

LOADING AND

MAINTENANCE AND

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INSPECTION

TROUBLESHOOTING APPENDICES INDEX

DIN rail: TH35-7.5Fe,

TH35-7.5Al, TH35-15Fe

35 (1.38)

115 (4.53)

Figure 10.12 External dimensions (Side view)

(49 (1.93))(49 (1.93))

98 (3.86)

(0.12)

Unit: mm (inch)

10.2 Module Installation

10.2.1 Precaution on installation

10 - 11

LOADING AND INSTALLATION

10.2.2 Instructions for mounting the base unit

When mounting the PLC to an enclosure or similar, fully consider its operability, maintainability and environmental resistance.

(1) Module mounting position

Keep the clearances shown in Figure 10.13 or Figure 10.19 between the top/bottom faces of the module and other structures or parts to ensure good ventilation and facilitate module replacement.

(a) In case of base unit

Indicates the panel top, wiring duct or any part position.

5mm (0.20 inch) or more

30mm(1.18 inch) or more *1

Panel

30mm(1.18 inch) or more

5mm (0.20 inch) or more

* 1: For wiring duct with 50mm (1.97 inch) or less height.

40nm (1.58inch) or more for other cases.

Figure 10.13 Module mounting position

Programmable logic controller

20mm (0.79 inch) or more

Door

10 - 12

10.2 Module Installation

10.2.2 Instructions for mounting the base unit

LOADING AND INSTALLATION

(2) Module mounting orientation

• Install the PLC in the orientation in Figure 10.14 to ensure good ventilation for heat release.

Figure 10.14 Orientation in which modules can be mounted

• Do not mount it in either of the orientations shown in Figure 10.15.

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Vertical mounting Horizontal installation

Horizontal mounting

Figure 10.15 Orientation in which modules cannot be mounted

TROUBLESHOOTING APPENDICES INDEX

10.2 Module Installation

10.2.2 Instructions for mounting the base unit

10 - 13

LOADING AND INSTALLATION

(3) Installation surface

Mount the base unit on a flat surface. If the mounting surface is not even, this may strain the printed circuit boards and cause malfunctions.

(4) Installation of unit in an area where the other devices are installed

Avoid mounting base unit in proximity to vibration sources such as large magnetic contractors and no-fuse circuit breakers; mount these on a separate panel or at a distance.

(5) Distances from the other devices

In order to avoid the effects of radiated noise and heat, provide the clearances indicated below between the PLC and devices that generate noise or heat (contactors and relays).

• Required clearance in front of PLC : at least 100 mm

• Required clearance on the right and left of PLC : at least 50 mm

(3.94 inch)

(1.97 inch).

At least 100mm (3.94 inch)

Contactor, relay, etc.

At least 50mm (1.97 inch)

Figure 10.16 Distances from the other devices

10 - 14

10.2 Module Installation

10.2.2 Instructions for mounting the base unit

LOADING AND INSTALLATION

10.2.3 Installation and removal of module

This section explains how to install and remove a power supply, CPU, I/O, intelligent function or another module to and from the base unit.

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DIRECTIVES

(1) Installation and removal of the module from the QS034B

(a) Installation of module on the QS034B

Securely insert the module fixing latch(*1) into the module fixing hole so that the latch is not misaligned.

Using the module fixing hole as a fulcrum, push the module in the direction of arrow to mount it into the base unit.

Check that the module is inserted in the base unit securely and then fix it with the module fixing screws.

Completed

* 1: The power supply module and CPU module has two module fixing latches. Insert the two module

Base unit

Unit fixing hook (*2)

Module

Module connector

Base unit

Module fixing

latch (*1)

Module loading

lever

Module fixing hole

Figure 10.17 Module mounting procedure

fixing latches on the right and left into the module fixing holes so that they are not misaligned.

Unit/Module

fixing latch

Module fixing hole

Module loading lever

LOADING AND

MAINTENANCE AND

INSTALLATION

INSPECTION

TROUBLESHOOTING APPENDICES INDEX

Module fixing hook

Base unit hook

Power supply module

Center top

Push

Figure 10.18 Mounting the power supply module and CPU module

* 2: The power supply module and CPU module has two module fixing hooks on its top. Push the

center top of the power supply module and CPU module and mount the module so that the two module fixing hooks on the right and left are securely engaged with the base unit hooks.

10.2 Module Installation

10.2.3 Installation and removal of module

10 - 15

LOADING AND INSTALLATION

POINT

1. When mounting the module, always insert the module fixing latch into the module fixing hole of the base unit. At that time, securely insert the module fixing latch so that it does not come off from the module fixing hole. If the module is forcibly mounted without the latch being inserted, the module connector and module will be damaged.

2. Do not mount/remove the module onto/from base unit more than 50 times (IEC61131-2-compliant), after the first use of the product. Failure to do so may cause the module to malfunction due to poor contact of connector.

10 - 16

10.2 Module Installation

10.2.3 Installation and removal of module

LOADING AND INSTALLATION

(b) Removal from the QS034B

Remove the module fixing screw. Then support the module with both

and securely press the

hands module fixing hook*1 with your finger.

Pull the module based on the supporting point of module bottom while pressing the module fixing hook .

While lifting the module, take the module fixing latch(*2) off the module fixing hole.

Push

Module fixing

hook *1

Module

connector

Unit/Module

Base unit

Module fixing hole

Lifting

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Completed

Figure 10.19 Module removal procedure

* 1: The power supply module and CPU module has two module fixing hooks on its top. Push the two

module fixing hooks on the right and left of the module top simultaneously with your fingers until they stop.

Push simultaneously

Module fixing hooks

Figure 10.20 Power supply module and CPU module removal procedure

* 2: The power supply module and CPU module has two module fixing latches. Remove the two

module fixing latches on the right and left of the module bottom from the module fixing holes.

MAINTENANCE AND

INSPECTION

TROUBLESHOOTING APPENDICES INDEX

POINT

When removing the module, always remove the module fixing screw(s) first, and then remove the module fixing projection(s) from the module fixing hole(s). Attempting to remove the module by force may damage the module fixing latch.

10.2 Module Installation

10.2.3 Installation and removal of module

10 - 17

10.3 Wiring

LOADING AND INSTALLATION

10.3.1 The precautions on the wiring

DANGER

Be sure to shut off all phases of the external supply power used by the

system before wiring. Not completely turning off all power could result in electric shock or damage to the product.

When energizing or operating the module after installation or wiring, be

sure to close the attached terminal cover. Not doing so may result in electric shock.

10 - 18

10.3 Wiring

10.3.1 The precautions on the wiring

LOADING AND INSTALLATION

CAUTION

Be sure to ground the FG terminals and LG terminals to the protective

ground conductor.Not doing so could result in electric shock or erroneous operation.

Use a solderless terminal with insulation sleeve for wiring of a terminal

block. Use up to two solderless terminals for a single terminal.

Use applicable solderless terminals and tighten them with the specified

torque. If any solderlessspade terminal is used, it may be disconnected when the terminal screw comes loose, resultingin failure.

Wire the module correctly after confirming the rated voltage and terminal

layout. Connecting a power supply of a different rated voltage or incorrect wiring may cause a fire or failure

Tighten a terminal block mounting screw, terminal screw, and module fix-

ing screw within the specified torque range. If the terminal block mounting screw or terminal screw is too loose, it may cause a short circuit, fire, or malfunctions. If too tight, it may damage the screw and/or the module, resulting in a drop of the screw or module, a short circuit or malfunctions. If the module fixing screw is too loose, it may cause a drop of the screw or module. Over tightening the screw may cause a drop due to the damage of the screw or module.

EMC AND LOW

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INSTALLATION

INSPECTION

TROUBLESHOOTING APPENDICES INDEX

Be sure there are no foreign substances such as sawdust or wiring debris

inside the module. Such debris could cause a fire, failure, or erroneous operation.

The module has an ingress prevention label on its top to prevent foreign

matter, such as wire offcuts, from entering the module during wiring. Do not peel this label during wiring. Before starting system operation, be sure to peel this label because of heat dissipation.

Install our PLC in a control panel for use.

Wire the main power supply to the power supply module installed in a control panel through a distribution terminal block. Furthermore, the wiring and replacement of a power supply module have to be performed by a maintenance worker who acquainted with shock protection. (For the wiring methods, refer to Section 10.3.)

The precautions on the connection of the power cables are described below.

10.3 Wiring

10.3.1 The precautions on the wiring

10 - 19

LOADING AND INSTALLATION

(1) Power supply wiring

• Separate the PLC's power supply line from the lines for I/O devices and power devices as shown below. When there is much noise, connect an insulation transformer.

• Taking rated current or inrush current into consideration when wiring the power supply, be sure to connect a breaker or an external fuse that have proper blown and detection. When using a single PLC, a 10A breaker or an external fuse are recommended for wiring protection.

Insulation Transformer

PLC

I/O equipment

Main circuit equipment

200VAC

Main power supply

Relay terminal block

On a control panel

Figure 10.21 Power supply connection diagram

PLC power supply

I/O power supply

Main circuit power supply

• 100VAC and 200VAC wires should be twisted as dense as possible. Connect the modules with the shortest distance. Also, to reduce the voltage drop to the minimum, use the thickest wires possible (maximum 2mm

• Do not bundle the 100VAC and 200VAC wires with, or run them close to, the main circuit (high voltage, large current) and I/O signal lines (including common line). Reserve a distance of at least 100 mm from adjacent wires.

• Momentary power failure may be detected or the CPU module may be reset due to serge caused by lightening. As measures against serge caused by lightening, connect a surge absorber for lightening as shown in Figure 10.22. Using the surge absorber for lightening can reduce the influence of lightening.

10 - 20

E1 E1

Figure 10.22 Connecting a lightning surge absorber

10.3 Wiring

10.3.1 The precautions on the wiring

PLC

I/O devices

Surge absorber for lightening

LOADING AND INSTALLATION

POINT

1. Separate the ground of the surge absorber for lightening (E1) from that of the PLC (E2).

2. Select a surge absorber for lightening whose power supply voltage does no exceed the maximum allowable circuit voltage even at the time of maximum power supply voltage elevation.

(2) Grounding

For grounding, perform the following:

• Use a dedicated grounding wire as far as possible. (Grounding resistance of

100 or less.)

• When a dedicated grounding cannot be performed, use (2) Common Grounding shown below.

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INSTALLATION

Another equipment

Grounding

Another equipment

Figure 10.23 Grounding procedures

PLC

(1) Independent grounding Best (2) Common grounding Good

PLC

• For grounding a cable, use the cable of 2 mm

Grounding

Another equipment

PLC

(3) Joint grounding Not allowed

or more. Position the ground-contact point as closely to the sequencer as possible, and reduce the length of the grounding cable as much as possible.

MAINTENANCE AND

INSPECTION

TROUBLESHOOTING APPENDICES INDEX

10.3 Wiring

10.3.1 The precautions on the wiring

10 - 21

LOADING AND INSTALLATION

10.3.2 Connecting to the power supply module

The following figure shows the wiring example of power lines, grounding lines, etc. to the unit.

100/110VAC

Fuse

AC DC

24VDC

Connect to 24VDC terminals of module that requires 24VDC internally.

* 1: The ERR. terminal turns ON/OFF as described below.

The terminal turns OFF (opens) when the AC power is not input, a CPU module stop error (including a reset) occurs, or the fuse of the power supply module is blown.

Main base unit

(QS034B)

QS061P-A1

Grounding

Figure 10.24 Wiring example

CPU module

Ground wire

ERR

FG LG

INPUT 100-120VAC

POINT

1. Use the thickest possible (max. 2 mm2 (14 AWG)) wires for the 100/200 VAC and 24 VDC power cables. Be sure to twist these wires starting at the connection terminals. For wiring a terminal block, be sure to use a solderless terminal. To prevent short-circuit due to loosening screws, use the solderless terminals with insulation sleeves of 0.8 mm (0.03 inch) or less thick. The number of the solderless terminals to be connected for one terminal block are limited to 2.

Solderless terminals

ith insulation sleeves

Terminal block

2.The ERR for ERR

10 - 22

10.3 Wiring

10.3.2 Connecting to the power supply module

. terminal can not be used as a safety output. In addition, set the cable

. contact in the control panel and its length to 30m (98.43 ft.) or less.

MAINTENANCE AND INSPECTION

CHAPTER11 MAINTENANCE AND INSPECTION

Do not touch the terminals while power is on.

DANGER

Doing so could cause shock or erroneous operation.

Correctly connect the battery.

Also, do not charge, disassemble, heat, place in fire, short circuit, or solder the battery. Mishandling of battery can cause overheating or cracks which could result in injury and fires.

Turn off all phases of the external supply power used in the system

when cleaning the module or retightening the terminal block mounting screws, terminal screws, or module fixing screws. Not doing so could result in electric shock. Tighten a terminal block mounting screw, terminal screw, and module fixing screw within the specified torque range. If the terminal block mounting screw or terminal screw is too loose, it may cause a short circuit, fire, or malfunctions. If too tight, it may damage the screw and/or the module, resulting in a drop of the screw or module, a short circuit or malfunctions. If the module fixing screw is too loose, it may cause a drop of the screw or module. Over tightening the screw may cause a drop due to the damage of the screw or module.

EMC AND LOW

VOLTAGE

LOADING AND

MAINTENANCE AND

DIRECTIVES

INSTALLATION

INSPECTION

TROUBLESHOOTING APPENDICES INDEX

11 - 1

MAINTENANCE AND INSPECTION

The online operations performed from a PC to a running safety

CAUTION

PLC (Program change when a safety CPU is RUN, device test, and operating status change such as RUN-STOP switching) have to be executed after the manual has been carefully read and the safety has been ensured. Following the operating procedure predetermined at designing, the operation has to be performed by an instructed person. When changing a program while a safety CPU is RUN (Write during RUN), it may cause a program breakdown in some operating conditions. Fully understand the precautions described in the GX Developer's manual before use.

Do not disassemble or modify the modules.

Doing so could cause a failure, erroneous operation, injury, or fire. If the product is repaired or remodeled by other than the specified FA centers or us, the warranty is not covered.

Use any radio communication device such as a cellular phone or a

PHS phone more than 25cm (9.85 inch) away in all directions of the PLC. Not doing so can cause a malfunction.

Completely turn off the externally supplied power used in the sys-

tem before mounting or removing the module. Not doing so may result in a failure or malfunctions of the module.

Restrict the mounting/removal of a module, base unit, and terminal

block up to 50 times (IEC61131-2-compliant), after the first use of the product. Failure to do so may cause the module to malfunction due to poor contact of connector.

Do not drop or give an impact to the battery mounted to the

module. Doing so may damage the battery, causing the battery fluid to leak inside the battery. If the battery is dropped or given an impact, dispose of it without using.

Before touching the module, always touch grounded metal, etc. to

discharge static electricity from human body, etc. Not doing so may result in a failure or malfunctions of the module.

11 - 2

In order that you can use the PLC in normal and optimal condition at all times, this section describes those items that must be maintained or inspected daily or at regular intervals.

11.1 Daily Inspection

MAINTENANCE AND INSPECTION

The items that must be inspected daily are listed in Table11.1.

Table11.1 Daily inspection

EMC AND LOW

VOLTAGE

DIRECTIVES

Item Inspection Item Inspection Judgment Criteria Remedy

1 Installation of base unit

Installation of power supply

module and CPU module

3 Connecting conditions

Power supply module "POWER" LED

CPU module "ALIVE" LED

CPU module "RUN"

LED

CPU module "ERR." LED

Module indication LED

CPU module "TEST" LED

CPU module "BAT." LED

Check that fixing screws are not loose and the cover is not dislocated.

Check that the module is not dislocated and the unit fixing hook is engaged securely.

Check that the module fixing screws are securely tightened.

Check for loose terminal screws.

Check for distance between solderless terminals.

Check that the LED is On (green).

Check that the LED is Off.

The screws and cover must be installed securely

The module fixing hook must be engaged and installed securely.

The module fixing screws must be securely tightened.

Screws should not be loose.

The proper clearance should be provided between Solderless terminals.

The LED must be On (green). (Abnormal if the LED is Off.)

The LED must be Off. (Abnormal if the LED is On or flashing.)

The LED must be Off. (Abnormal if the LED is On.)

Retighten the screws.

Securely engaged the unit fixing hook.

Securely tighten the module fixing screws.

Retighten the terminal screws.

Correct.

Since the status other than indicated on the left is in the status other

than normal operation perform the troubleshooting referring to Section

12.2.

LOADING AND

INSTALLATION

MAINTENANCE AND

INSPECTION

TROUBLESHOOTING APPENDICES INDEX

*1: Normal operation indicates the following conditions.

• Safety CPU operation mode is in the SAFETY MODE.

• The CPU operation status is in the RUN status.

11.1 Daily Inspection

11 - 3

MAINTENANCE AND INSPECTION

11.2 Periodic Inspection

The items that must be inspected one or two times every 6 months to 1 year are listed below. When the equipment is moved or modified, or layout of the wiring is changed, also perform this inspection.

Table11.2 Periodic Inspection

Item Inspection Item Inspection Judgment Criteria Remedy

Ambient temperature

Ambient humidity 5 to 95 %RH

Atmosphere

Ambient environment

2 Power voltage

Measure with a thermometer and a hygrometer. Measure corrosive gas.

Measure a voltage across the terminals of 100/ 200VAC.

0 to 55

Corrosive gas must not be present.

85 to 132VAC

170 to 264VAC

When the sequencer is used in the board, the ambient temperature in the board becomes the ambient temperature.

Change the power supply.

Looseness, rattling

Installation

Adhesion of dirt and foreign matter

Looseness of terminal screws

5Battery

7 Clock

Proximity of solderless terminals to each other

Connection

Looseness of connectors

Number of writes to standard ROM

Move the module to check for looseness and rattling.

Check visually.

Try to further tighten screws with a screwdriver.

Check visually.

Check "BAT." LED on the front face of the CPU module.

Check the period after the purchase of the battery.

Check in the monitoring mode of GX Developer that SM51 or SM52 is turned OFF.

Check the values of SD232 and SD233 in the monitoring mode of GX Developer.

Check the current time at the clock setting of GX Developer.

The module must be installed fixedly.

Dirt and foreign matter must not be present.

Screws must not be loose.

Solderless terminals must be positioned at proper intervals.

Connectors must not be loose.

The LED must be Off.

The period must be five years or less.

SM51 or SM52 must be OFF.

The number of writes to the standard ROM must be 100,000 times or less.

There is no time lag between the time checked at the time setting of GX Developer and the actual time.

Retighten the screws. If the CPU, or power supply module is loose, fix it with screws.

Remove and clean.

Retighten the terminal screws.

Correct.

Retighten the connector fixing screws.

If the LED is On, replace the battery.

If the battery is used for more than 5 years, replace the battery.

If SM51 or SM52 is ON, replace the battery.

If the number of writes to the standard ROM exceeds 100,000 times, replace the CPU module.

Change the time at the time setting of GX Developer.

11 - 4

11.2 Periodic Inspection

11.3 Battery Life and Replacement Procedure

MAINTENANCE AND INSPECTION

The battery installed in the CPU module is used for data retention during the power failure of the program memory and error/operation history. Special relays SM51 and SM52 turn on due to the decrease of battery voltage. Even if the special relays turn on, the program and error/operation history data are not erased immediately. After relay SM51 turns on, replace the battery quickly within the data retention time for power failure (3 minutes).

POINT

SM51 turns on when the battery voltage falls below the specified value, and remains ON even after the voltage is recovered to the normal value. SM52 turns on when the battery voltage falls below the specified value, and turns OFF when the voltage is recovered to the normal value. After SM51 and/or SM52 turns on, replace the battery quickly.

EMC AND LOW

VOLTAGE

LOADING AND

DIRECTIVES

INSTALLATION

SM51 and SM52 turn on when the battery voltage of the CPU module is lowered. The battery voltage drop can be checked with the contents of the special registers SD51 and SD52.

b15 b1 b0to

SD51, SD52

For details of SD51 and SD52, refer to Section 12.7.

Fixed at 0

Error of a CPU module battery

Figure 11.1 Bit pattern

When the battery voltage is low, the value is "1."

MAINTENANCE AND

INSPECTION

TROUBLESHOOTING APPENDICES INDEX

11.3 Battery Life and Replacement Procedure

11 - 5

MAINTENANCE AND INSPECTION

11.3.1 Battery lives of CPU modules

Table11.3 Battery lives

CPU Module

Typ e

QS001CPU

* 1: The power-on time ratio indicates the ratio of PLC power-on time to one day (24 hours).

* 2: The guaranteed battery service life; equivalent to the total power failure time that is calculated

* 3: The actual battery service life; equivalent to the total power failure time that is calculated based on

* 4: In the following status, the backup time after power OFF is 3 minutes.

Power-on Time

Ratio

30%

50%

70%

100%

(When the total power-on time is 12 hours and the total power-off time is 12 hours, the power-on time ratio is 50%.)

based on the characteristics value of the memory (SRAM) supplied by the manufacturer and

under the storage ambient temperature range of -40 to 75 (operating ambient temperature of 0

to 55 ).

the measured value and under the storage ambient temperature of 40 . This value is intended for reference only, as it varies with characteristics of the memory.

•The battery connector is disconnected.

•The lead wire of the battery is broken.

value (70 )

Guaranteed

26,000hr

2.96 years

37,142hr

4.23 years

43,800hr

5.00 years

43,800hr

5.00 years

43,800hr

5.00 years

Battery lives

Actual service

value (Reference

value)

43,800hr

5.00 years

43,800hr

5.00 years

43,800hr

5.00 years

43,800hr

5.00 years

43,800hr

5.00 years

(40 )

After SM52 ON

(Backup time after

alarm

)

710hr

30 days

710hr

30 days

710hr

30 days

710hr

30 days

710hr

30 days

11 - 6

11.3 Battery Life and Replacement Procedure

11.3.1 Battery lives of CPU modules

MAINTENANCE AND INSPECTION

POINT

1. Do not use the battery exceeding its guaranteed life. If it is expected that the battery may exceed its guaranteed life, take the following measures:

• Back up programs and the error/operation history in advance after SM52 turns on (within the power failure compensation time after alarm occurrence).

2. The life of Q6BAT is 5 years when not connected to a CPU module.

3. When the battery-low special relay SM52 turns on, immediately change the battery. If an alarm has not yet occurred, it is recommended to replace the battery periodically according to the conditions of use.

EMC AND LOW

VOLTAGE

LOADING AND

MAINTENANCE AND

DIRECTIVES

INSTALLATION

INSPECTION

TROUBLESHOOTING APPENDICES INDEX

11.3 Battery Life and Replacement Procedure

11.3.1 Battery lives of CPU modules

11 - 7

BAT.

MAINTENANCE AND INSPECTION

11.3.2 Replacement Procedure of the CPU Module Battery

Replace the battery by the following procedure when the Q6BAT battery of the CPU module comes to the end of its life. The battery replacement can be performed regardless of the SAFETY MODE or TEST MODE. The PLC power must be on for 10 minutes or longer before dismounting the battery. Data in the memory are backed up for a while by a capacitor even after the battery is removed. However, since data in the memory may be erased if the time for replacement exceeds the backup time shown in Table11.4, replace the battery quickly.

Table11.4 Backup time

Backup time

3 minutes

Battery replacement

Save the error/operation history data as a file with GX Developer. (*1)

Turn off the PLC.

Open the CPU module front cover.

Remove the old battery from its holder.

Insert a new battery into the holder in the correct direction. Connect the lead connector to the connector.

Close the CPU module front cover.

Turn on the PLC.

The CPU module backs up the error/operation history data with a

*1:

battery. In the SAFETY MODE, sequence programs and parameters are saved in the standard ROM. When replacing the battery, save the error/operation history data as a backup file with GX Developer. For details, refer to the GX Developer Version 8 Operating Manual (Safety PLC).

CPU module

BAT.

PULL

STOP

RUN

RESET

Connector of

CPU module side

Connector

of battery side

11 - 8

Monitor

SM51 to verify

ON/OFF.

Monitor

SD52 to check if bit 0 is

ON.

Bit 0 is ON.

Failure of the replaced battery

Figure 11.2 Replacement procedure for the Q6BAT battery

OFF

Bit 0 is OFF.

11.3 Battery Life and Replacement Procedure

11.3.2 Replacement Procedure of the CPU Module Battery

Completed

11.4 When PLC Has been Stored without a Battery

MAINTENANCE AND INSPECTION

When the PLC operation is to be resumed after being stored with the battery removed, the memories in the CPU module may be corrupted. Hence, before resuming operation, always format the memories using GX Developer. After formatting the memories, write the memory contents backed up prior to storage to each memory.

The relationships between battery and battery-backed memorie are shown in Table11.5.

EMC AND LOW

VOLTAGE

DIRECTIVES

Table11.5 Relationships between the battery and battery-backed memories

Memory

CPU module

Format the battery-backed memories in Table11.5 using GX Developer before resuming operation.

For information about the memory formatting, refer to the manual below.

GX Developer Operating Manual

Program memory

Standard ROM ---- (Battery backup not needed)

: Battery backed, : Not battery backed

Battery

Q6BAT

POINT

1. Before storing the PLC, always back up the contents of each memory.

2. The operation/error history cannot be written to the memory from GX Developer.

LOADING AND

MAINTENANCE AND

INSTALLATION

INSPECTION

TROUBLESHOOTING APPENDICES INDEX

11.4 When PLC Has been Stored without a Battery

11 - 9

11.5 When Battery Has Gone Flat during Storage of a PLC

MAINTENANCE AND INSPECTION

When the PLC is to be used after being stored for some period of time and the battery has gone flat during storage, the memories in the CPU module may be corrupted. Hence, before resuming operation, always format the memories using GX Developer. After formatting the memories, write the memory contents backed up prior to storage to each memory.

The relationships between battery and battery-backed memorie are shown in Table11.6.

Table11.6 Relationships between the battery and battery-backed memories

Memory

CPU module

Format the battery-backed memories in Table11.6 using GX Developer before resuming operation.

For information about the memory formatting, refer to the manual below.

GX Developer Operating Manual

Program memory

Standard ROM ---- (Battery backup not needed)

: Battery backed, : Not battery backed

Battery

Q6BAT

POINT

1. Before storing the PLC, always back up the contents of each memory.

2. The operation/error history cannot be written to the memory from GX Developer.

11 - 10

11.5 When Battery Has Gone Flat during Storage of a PLC

Mitsubishi MELSEC, QSCPU, QS User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SAFETY PRECAUTIONS

REVISIONS

INTRODUCTION

CONTENTS

ABOUT MANUALS

HOW THIS MANUAL IS ORGANIZED

HOW TO USE THIS MANUAL

GENERIC TERMS AND ABBREVIATIONS

PRECAUTIONS FOR USE

CHAPTER1 OVERVIEW

1.1 Features

CHAPTER2 SYSTEM CONFIGURATION

2.1 System Configuration

2.1.1 Precautions for system configuration

2.2 Configuration of Peripheral Devices

2.3 Confirming Serial No. and Function Version

CHAPTER3 GENERAL SPECIFICATIONS

CHAPTER4 CPU MODULE

4.1 Performance Specifications

4.2 Part Names

4.3 Switch Operation after Writing a Program

4.4 Reset Operation

CHAPTER5 POWER SUPPLY MODULE

5.1 Specifications

5.2 Precaution when connecting the uninterruptive power supply

5.3 Names of Parts and Settings

CHAPTER6 BASE UNIT

6.1 Specification

6.2 Part Names

CHAPTER7 BATTERY

7.1 Battery (Q6BAT)

7.1.1 Battery Specifications

7.1.2 Installation of Battery

CHAPTER8 CPU MODULE START-UP PROCEDURES

8.1 Procedure before Operating in SAFETY MODE

CHAPTER9 EMC AND LOW VOLTAGE DIRECTIVES

9.1 Requirements for Conformance to EMC Directive

9.1.1 Standards relevant to the EMC Directive

9.1.2 Installation instructions for EMC Directive

9.1.3 Cables

9.1.4 Power Supply Module

9.1.5 Others

9.2 Requirement to Conform to the Low Voltage Directive

9.2.1 Standard applied for MELSEC-QS series PLC

9.2.2 MELSEC-QS series PLC selection

9.2.3 Power supply

9.2.4 Control panel

9.2.5 Grounding

9.2.6 External wiring

CHAPTER10 LOADING AND INSTALLATION

10.1 Calculating Heat Generation of PLC

10.2 Module Installation

10.2.1 Precaution on installation

10.2.2 Instructions for mounting the base unit

10.2.3 Installation and removal of module

10.3 Wiring

10.3.1 The precautions on the wiring

10.3.2 Connecting to the power supply module

CHAPTER11 MAINTENANCE AND INSPECTION

11.1 Daily Inspection

11.2 Periodic Inspection

11.3 Battery Life and Replacement Procedure

11.3.1 Battery lives of CPU modules

11.3.2 Replacement Procedure of the CPU Module Battery

11.4 When PLC Has been Stored without a Battery

11.5 When Battery Has Gone Flat during Storage of a PLC