Mitsubishi Electric MELSEC iQ-R Series Instruction sheet

MELSEC iQ-R

Module Configuration Manual

SAFETY PRECAUTIONS

(Read these precautions before using this product.)

Before using MELSEC iQ-R series programmable controllers, please read the manuals for the product and the relevant

manuals introduced in those manuals carefully, and pay full attention to safety to handle the product correctly.

In this manual, the safety precautions are classified into two levels: " WARNING" and " CAUTION".

Under some circumstances, failure to observe the precautions given under " CAUTION" may lead to serious

consequences.

Observe the precautions of both levels because they are important for personal and system safety.

Make sure that the end users read this manual and then keep the manual in a safe place for future reference.

WARNING Indicates that incorrect handling may cause hazardous conditions, resulting in

death or severe injury.

CAUTION Indicates that incorrect handling may cause hazardous conditions, resulting in

minor or moderate injury or property damage.

[Design Precautions]

WARNING

●Configure safety circuits external to the programmable controller to ensure that the entire system

operates safely even when a fault occurs in the external power supply or the programmable controller.

Failure to do so may result in an accident due to an incorrect output or malfunction.

(1) Emergency stop circuits, protection circuits, and protective interlock circuits for conflicting

operations (such as forward/reverse rotations or upper/lower limit positioning) must be configured

external to the programmable controller.

(2) When the programmable controller detects an abnormal condition, it stops the operation and all

outputs are:

• Turned off if the overcurrent or overvoltage protection of the power supply module is activated.

• Held or turned off according to the parameter setting if the self-diagnostic function of the CPU

module detects an error such as a watchdog timer error.

(3) All outputs may be turned on if an error occurs in a part, such as an I/O control part, where the

CPU module cannot detect any error. To ensure safety operation in such a case, provide a safety

mechanism or a fail-safe circuit external to the programmable controller. For a fail-safe circuit

example, refer to Page 187 General Safety Requirements in this manual.

(4) Outputs may remain on or off due to a failure of a component such as a relay and transistor in an

output circuit. Configure an external circuit for monitoring output signals that could cause a

serious accident.

●In an output circuit, when a load current exceeding the rated current or an overcurrent caused by a

load short-circuit flows for a long time, it may cause smoke and fire. To prevent this, configure an

external safety circuit, such as a fuse.

●Configure a circuit so that the programmable controller is turned on first and then the external power

supply. If the external power supply is turned on first, an accident may occur due to an incorrect output

or malfunction.

●For the operating status of each station after a communication failure, refer to manuals relevant to the

network. Incorrect output or malfunction due to a communication failure may result in an accident.

●When connecting an external device with a CPU module or intelligent function module to modify data

of a running programmable controller, configure an interlock circuit in the program to ensure that the

entire system will always operate safely. For other forms of control (such as program modification,

parameter change, forced output, or operating status change) of a running programmable controller,

read the relevant manuals carefully and ensure that the operation is safe before proceeding. Improper

operation may damage machines or cause accidents.

[Design Precautions]

WARNING

●Especially, when a remote programmable controller is controlled by an external device, immediate

action cannot be taken if a problem occurs in the programmable controller due to a communication

failure. To prevent this, configure an interlock circuit in the program, and determine corrective actions

to be taken between the external device and CPU module in case of a communication failure.

●Do not write any data to the "system area" and "write-protect area" of the buffer memory in the

module. Also, do not use any "use prohibited" signals as an output signal from the CPU module to

each module. Doing so may cause malfunction of the programmable controller system. For the

"system area", "write-protect area", and the "use prohibited" signals, refer to the user's manual for the

module used.

●If a communication cable is disconnected, the network may be unstable, resulting in a communication

failure of multiple stations. Configure an interlock circuit in the program to ensure that the entire

system will always operate safely even if communications fail. Incorrect output or malfunction due to a

communication failure may result in an accident.

●To maintain the safety of the programmable controller system against unauthorized access from

external devices via the network, take appropriate measures. To maintain the safety against

unauthorized access via the Internet, take measures such as installing a firewall.

[Precautions for using digital-analog converter modules and high speed digital-analog

converter modules]

●Analog outputs may remain on due to a failure of the module. Configure an external interlock circuit

for output signals that could cause a serious accident.

[Design Precautions]

WARNING

[Precautions for using high-speed counter modules and flexible high-speed I/O control

modules]

●Outputs may remain on or off due to a failure of a transistor for external output. Configure an external

circuit for monitoring output signals that could cause a serious accident.

[Precautions for using flexible high-speed I/O control modules]

●When changing data and operating status of the running module from an external device such as a

personal computer connected, configure an interlock circuit external to the programmable controller to

ensure that the entire system always operates safely. In addition, before performing online operations,

determine corrective actions to be taken between the external device and the module in case of a

communication failure due to poor contact of cables.

[Precautions for using positioning modules and Simple Motion modules]

●Configure safety circuits external to the programmable controller to ensure that the entire system

operates safely even when a fault occurs in the external power supply or the programmable controller.

Failure to do so may result in an accident due to an incorrect output or malfunction.

(1) Machine OPR (Original Point Return) is controlled by two kinds of data: an OPR direction and an

OPR speed. Deceleration starts when the near-point dog signal turns on. If an incorrect OPR

direction is set, motion control may continue without deceleration. To prevent machine damage

caused by this, configure an interlock circuit external to the programmable controller.

(2) When the positioning module detects an error, the motion slows down and stops or the motion

suddenly stops, depending on the stop group setting in parameter. Set the parameters to meet the

specifications of the positioning control system used. In addition, set the OPR parameters and

positioning data within the specified setting range.

(3) Outputs may remain on or off, or become undefined due to a failure of a component such as an

insulation element and transistor in an output circuit, where the positioning module cannot detect

any error. In a system where the incorrect outputs could cause a serious accident, configure an

external circuit for monitoring output signals.

●An absolute position restoration by the positioning module may turn off the servo-on signal (servo off)

for approximately 60ms + scan time, and the motor may run unexpectedly. If this causes a problem,

provide an electromagnetic brake to lock the motor during absolute position restoration.

[Design Precautions]

WARNING

[Precautions for using Motion CPU modules and Simple Motion modules]

●Configure safety circuits external to the programmable controller to ensure that the entire system

operates safely even when a fault occurs in the external power supply or the programmable controller.

Failure to do so may result in an accident due to an incorrect output or malfunction.

●If safety standards (ex., robot safety rules, etc.,) apply to the system using the module, servo amplifier

and servo motor, make sure that the safety standards are satisfied.

●Construct a safety circuit externally of the module or servo amplifier if the abnormal operation of the

module or servo amplifier differs from the safety directive operation in the system.

●Do not remove the SSCNETcable while turning on the control circuit power supply of modules and

servo amplifier. Do not see directly the light generated from SSCNETconnector of the module or

servo amplifier and the end of SSCNETcable. When the light gets into eyes, you may feel

something wrong with eyes. (The light source of SSCNETcomplies with class1 defined in JISC6802

or IEC60825-1.)

[Precautions for using CC-Link IE Controller Network (when optical fiber cables are used)]

●The optical transmitter and receiver of the CC-Link IE Controller Network module use laser diodes

(class 1 in accordance with IEC 60825-1). Do not look directly at a laser beam. Doing so may harm

your eyes.

[Precautions for using CC-Link system master/local modules]

●To set a refresh device in the module parameters, select the device Y for the remote output (RY)

refresh device. If a device other than Y, such as M and L, is selected, the CPU module holds the

device status even after its status is changed to STOP. For how to stop data link, refer to the MELSEC

iQ-R CC-Link System Master/Local Module User's Manual (Application).

[Precautions for using C Controller modules]

●In the settings of refresh parameters, link output (LY) refresh devices and remote output (RY) refresh

devices do not allow the specification of Y. Thus, the CPU module holds the device status even after

its status is changed to STOP.

[Precautions for using redundant function modules]

●The optical transmitter and receiver of the redundant function module use laser diodes (class 1 in

accordance with IEC 60825-1). Do not look directly at a laser beam. Doing so may harm your eyes.

[Precautions for using products in a Class , Division 2 environment]

●Products with the Cl., DIV.2 mark on the rating plate are suitable for use in Class , Division 2,

Groups A, B, C and D hazardous locations, or nonhazardous locations only.

This mark indicates that the product is certified for use in the Class , Division 2 environment where

flammable gases, vapors, or liquids exist under abnormal conditions. When using the products in

the Class , Division 2 environment, observe the following to reduce the risk of explosion.

• This device is open-type and is to be installed in an enclosure suitable for the environment and

require a tool or key to open.

• Warning - Explosion Hazard - Substitution of any component may impair suitability for Class ,

Division 2.

• Warning - Explosion Hazard - Do not disconnect equipment while the circuit is live or unless the

area is known to be free of ignitable concentrations.

• Do not open the cover of the CPU module and remove the battery unless the area is known to

be nonhazardous.

• All MELSEC iQ-R modules (except base modules) are to be connected to a base module only.

[Design Precautions]

WARNING

[Precautions for using Safety CPUs]

●When the safety programmable controller detects a fault in the external power supply or itself, it turns

off all outputs in the safety system. Configure an external circuit to ensure that the power source of a

hazard is shut off by turning off the outputs. Failure to do so may result in an accident.

●Configure short current protection circuits for safety relays and protection circuits, such as a fuse and

breaker, external to the safety programmable controller.

●When a load current exceeding the rated current or an overcurrent caused by a load short-circuit

flows, the CC-Link IE Field Network remote I/O module (with safety functions) detects an error and

turns off all outputs. Note that if the overcurrent state continues for a long time, it may cause smoke

and fire. To prevent this, configure an external safety circuit, such as a fuse.

●When changing data and operating status, and modifying program of the running safety

programmable controller from an external device such as a personal computer connected to the

Safety CPU, configure an interlock circuit in the program or external to the safety programmable

controller to ensure that the entire system always operates safely. In addition, before performing

online operations, determine corrective actions to be taken between the external device and Safety

CPU in case of a communication failure due to poor contact of cables.

●Do not use any "use prohibited" signals as a remote I/O signal since they are used by the system. Do

not write any data to the "use prohibited" areas in the remote register. For the "use prohibited" signals,

refer to the MELSEC iQ-R CC-Link IE Field Network User's Manual (Application). Do not turn on or off

these signals on a program since normal operations cannot be guaranteed. Doing so may cause

malfunction of the programmable controller system.

●When the CC-Link IE Field Network remote I/O module (with safety functions) detects a CC-Link IE

Field Network error, it turns off outputs. However, the program does not automatically turn off outputs.

Create a program that turns off outputs when a CC-Link IE Field Network error is detected. If CC-Link

IE Field Network is restored with outputs on, connected machines may suddenly operate, resulting in

an accident.

●Create an interlock circuit which uses reset buttons so that the system does not restart automatically

after executing safety functions and turning off outputs.

●In the case of a communication failure in the network, the status of the error station will be as follows:

(1) All inputs from remote I/O stations are turned off.

(2) All outputs from remote I/O stations are turned off.

Check the communication status information and configure an interlock circuit in the program to

ensure that the entire system will operate safely. Failure to do so may result in an accident due to an

incorrect output or malfunction.

●Outputs may remain on or off due to a failure of the CC-Link IE Field Network remote I/O module (with

safety functions). Configure an external circuit for monitoring output signals that could cause a serious

accident.

[Design Precautions]

WARNING

[Precautions for using remote head modules]

●Configure safety circuits external to the remote head module to ensure that the entire system

operates safely even when a fault occurs in the external power supply or the remote head module.

Failure to do so may result in an accident due to an incorrect output or malfunction.

(1) Emergency stop circuits, protection circuits, and protective interlock circuits for conflicting

operations (such as forward/reverse rotations or upper/lower limit positioning) must be configured

external to the remote head module.

(2) When the remote head module detects an abnormal condition, outputs are:

• Held or turned off according to the parameter setting of each module mounted on the main

base unit or extension base unit if the self-diagnostic function of the remote head module

detects an error such as a watchdog timer error.

(3) All outputs may be turned on if an error occurs in a part, such as an I/O control part, where the

remote head module cannot detect any error. To ensure safety operation in such a case, provide a

safety mechanism or a fail-safe circuit external to the remote head module. For a fail-safe circuit

example, refer to Page 187 General Safety Requirements in this manual.

●Configure a circuit so that the remote head module is turned on first and then the external power

supply. If the external power supply is turned on first, an accident may occur due to an incorrect output

or malfunction.

●When connecting an external device with a remote head module to modify data of a running remote

head module, configure an interlock circuit in the program of the master station to ensure that the

entire system will always operate safely. For other forms of control (such as parameter change, forced

output, or operating status change) of a running remote head module, read the relevant manuals

carefully and ensure that the operation is safe before proceeding. Improper operation may damage

machines or cause accidents.

●Especially, when a remote head module is remotely controlled by an external device, immediate

action cannot be taken if a problem occurs in the remote head module due to a communication failure.

To prevent this, configure an interlock circuit in the program of the master station, and determine

corrective actions to be taken between the external device and remote head module in case of a

communication failure.

●Do not write any data to the buffer memory in the remote head module. Doing so may cause

malfunction of the programmable controller system.

●Do not write any data from the remote head module to the "system area" and "write-protect area" of

the buffer memory in each module. Also, do not use any "use prohibited" signals as an output signal

from the remote head module to each module. Doing so may cause malfunction of the programmable

controller system. For the "system area", "write-protect area", and the "use prohibited" signals, refer to

the user's manual for the module used.

[Precautions for using AnyWireASLINK master modules]

●An AnyWireASLINK system has no control function for ensuring safety.

[Design Precautions]

CAUTION

●Do not install the control lines or communication cables together with the main circuit lines or power

cables. Keep a distance of 100mm or more between them. Failure to do so may result in malfunction

due to noise.

●During control of an inductive load such as a lamp, heater, or solenoid valve, a large current

(approximately ten times greater than normal) may flow when the output is turned from off to on.

Therefore, use a module that has a sufficient current rating.

●After the CPU module is powered on or is reset, the time taken to enter the RUN status varies

depending on the system configuration, parameter settings, and/or program size. Design circuits so

that the entire system will always operate safely, regardless of the time.

●Do not power off the programmable controller or reset the CPU module while the settings are being

written. Doing so will make the data in the flash ROM and SD memory card undefined. The values

need to be set in the buffer memory and written to the flash ROM and SD memory card again. Doing

so also may cause malfunction or failure of the module.

●When changing the operating status of the CPU module from external devices (such as the remote

RUN/STOP functions), select "Do Not Open by Program" for "Opening Method" of "Module

Parameter". If "Open by Program" is selected, an execution of the remote STOP function causes the

communication line to close. Consequently, the CPU module cannot reopen the line, and external

devices cannot execute the remote RUN function.

[Precautions for using digital-analog converter modules and high speed digital-analog

converter modules]

●Power on or off the external power supply while the programmable controller is on. Failure to do so

may result in incorrect output or malfunction.

●At on/off of the power or external power supply, or at the output range switching, a voltage may occur

or a current may flow between output terminals for a moment. In this case, start the control after

analog outputs become stable.

[Precautions for using high-speed counter modules and flexible high-speed I/O control

modules]

●Do not install the control lines or communication cables together with the main circuit lines or power

cables. Keep a distance of 150mm or more between them. Failure to do so may result in malfunction

due to noise.

[Precautions for using Safety CPUs]

●When selecting external devices to be connected to the CC-Link IE Field Network remote I/O module

(with safety functions), consider the maximum inrush current described in the CC-Link IE Field

Network Remote I/O Module (With Safety Functions) User's Manual. Exceeding the maximum inrush

current may cause malfunction or failure of the module.

[Precautions for using remote head modules]

●After the remote head module is powered on or is reset, the time taken to enter the RUN status varies

depending on the system configuration and/or parameter settings. Design circuits so that the entire

system will always operate safely, regardless of the time.

●Do not power off or reset the remote head module while the parameters are being written. Doing so

may cause malfunction or failure of the module.

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