Automation solutions guide

Automation Solutions Guide

Industry Solutions Mitsubishi Electric has established a strong reputation for providing high performance products to build powerful solutions. With extensive global experience in the packaging, material handling, automotive, machine tool, and water industries, our knowledge base and application know-how continues to expand.

Application solutions bring added value to startup projects, reducing extra programming and troubleshooting time, ultimately saving several days or weeks of work. Identifying and utilizing the important product features for a specific application can be a challenging task for someone who is new to Mitsubishi. Through documented success stories, quick start documentation and detailed technical notes, it becomes much easier to learn the methods needed to propel a project forward.

Table of Contents Endless custom solutions for any industrial environment...

Industry Solutions

2-13

Controllers • automobile manufacturing • bottling • semiconductor manufacturing • machine tool operations • electrical plants

PLC Overview Alpha2 FX Series L Series iQ Platform/Q Series Networks

14 15 16-17 18-19 20-21 22-23

• packaging • parts assembly • food preparation • water treatment • material handling • electronic testing • printing • distillation processing • recycling plants

Motion Servo Systems Pulse Train Positioning Single-Axis Motion Controller Q Series Drives

30-31

Packaged Solutions

32

Low Voltage Switchgear

33

Human Machine Interfaces

34-35

Software

36-39

Robots

40-41

CNC

42-43

Support & Services

44-45

• pharmaceutical manufacturing • metal die cutting

24-26 27 28 29

• textile assembly • plastic injection • oil production • food packaging • steel fabrication • furniture manufacturing • fermentation processing • software manufacturing • building assembly • shipping and receiving

1

Example Applications Rotary knife applications can be adapted to perform a variety of functions. Some of the example machine applications include: • Steel and paper cutting • Perforation • Labeling • Stamping • Flat material sealing • Scanning

Rotary Knife Mark Sensor

Encoder

GT12 GT16

-B MR-J3-B Safetyy MR-J3-D01 I/O Card

Ethernet or

HF-JP / HF-MP

GT10 MR-MQ100

Overview Rotary knife applications include an axis of servo that responds intelligently to incoming pulses from an encoder to cut a material that is moving. Typically, the servo axis rotates continuously to perform a cutting action while responding dynamically to any fluctuations in the line speed or product length. A synchronous encoder following function is used in combination with high speed registration.

Vertical Form, Fill and Seal

Applications suitable for vertical form, fill and seal operations include but are not limited to: • Food/beverage bag filling • Pouch packaging • Industrial powder filling

Q170MCPU

Registration Mark Detection Sensor*2

Example Applications

Feeder QX40

Low Roll Detection Sensor*2

QY40P

Q64TCTT

Vertical thermal heat sealer Tension Control Coil Spring Lever

Vertical Film Index Drives Sealing and Cutting Arms

RS232

Industry Solutions

Rotary Knife

MR-J3-B Safety

Product Present Sensor*2

E700

GT16 RS485

*1)

Proximity Safety Sensor*1

*2)

Overview Vertical form, fill and seal applications utilize servo motor technology to accurately pull and feed plastic film material from a roll stock to be heat formed, volume dosed with a product, and then sealed and cut to be carried away by an unloading conveyor. While the methods for filling and sealing vary from machine to machine, vertical form, fill and seal applications are essentially organized into two categories: Continuous motion bagging machines, intermittent motion bagging machines.

Product entering the feeder can vary from a viscous fluid to a solid material and will often play a key role in how the machine is designed.

2

Industry Solutions

Industry Solutions

Filling with PackML Implementation Example Applications

Form & seal Heating to form

• Juice box filling • Food/medicine powder filling • Liquid packaging • Carton filling • Paint filling • Soap and detergent filling

RV-SQ Pick & Place

Filling

CR2Q-711

GT16

POW

CPU 0

1

2

3

4

5

6

7

Q03UDE Q172D Q64TCTT Q12DCCPU-V QY40P Q172DR QX40

MR-J3-B Safety

Overview Filling applications in the packaging industry load containers onto a conveyor to be filled with a viscous liquid and then sealed shut for distribution. A loading arm rotates each container to be formed with heat before placement onto a conveyor.

The conveyor then carries each product toward a filler station while coordinating movement with two servos to perform the filling process. As an option, a robot is used to pick and place the containers onto a pallet.

Mitsubishi Electric provides a complete solution through combining PLC, HMI, motion, and robot programming products under one platform.

Wrapping Machines Example Applications Flying Shear Cutting

Wrapping applications in the packaging industry can be used to package a wide range of different products. Example applications include: • Bottle and case wrapping • Box wrapping • Tray overwrapping • Shrink wrapping

Heating Chamber

Servo #1 Web Tracking Sensor*2

Low Roll Detection Sensor*2

Safety Interlock*1 Encoder

Indexer

Tray Present Sensor*2

GT15 Q170MCPU

Servo #2

Q55B

MR-J3-B Safety *1)

E700 A7NC

QX48Y57 Q64TCTT

QD81DL96 QJ61BT11N

*2)

Overview Wrapping machines in the packaging industry are often placed at the end of manufacturing lines in order to wrap products in plastic film material for shipment. The application highlighted here provides a high-end servo solution for cutting plastic material with a flying shear operation so that products can continually move forward. A second indexing servo axis assists in spacing the products at equal distances on the main conveyor. A large number of wrapping solutions can also be done through combining a series of indexing movements.

Industry Solutions

3

Industry Solutions

Labeling Machines Low Roll Label Detection Sensor*2

Example Applications Labeling technology is applied to attach labels in a variety of applications including: • Food and beverage machines • Pharmaceutical • Material handling machines • Mailing • Bottles and cans • Stationary goods

Web Tracking Sensor*2

Servo motor Label Sensor

Vision System*1

Product Present Sensor*2

Q170MCPU GT16 RS232 Encoder

et ern Eth

E700

*1)

Vision System

*2)

MR-J3-B MR J3 B Safety

Overview

QX40 QY40P

High-speed labeling machines require registration and encoder following in order to accurately position labels at different speeds. In-line labeling systems such as the machine shown above place labels on block shaped products that move in a single direction. Rotary labeling machines place labels on cylindrical products that rotate around a central label head.

When more than one label is placed on a product, multiple label heads can be configured with additional servos and sensors.

Mitsubishi Electric’s stand alone motion controller offers the flexibility to add these intelligent axes, and for additional trend analysis and quality control, a vision system can be used to track defective products and monitor label accuracy.

Bag Manufacturing Example Applications Bag manufacturing machines can be used to create the following types of bags: • Produce grocery bags • Garbage bags • Food bags • Candy bags

Roll Diameter Sensor *1

Dancer Arm Position Sensor *1

Cut & Seal (Ax.2)

Web Tracking Sensor *1

Counter-traverse (Ax.3)

Out-feed (Ax.4) Encoder

Serial

POW

In-feed (Ax.1)

CPU 0

1

2

3

4

5

6

7

GT15 Q03UDCPU Q12DCCPU-V QD75MH4

QX48Y57 QD62E

MR-J3-B 3 Safety S f

Q64AD *1)

Overview Bag manufacturing machines create rolls of trash bags or produce bags while also creating perforated marks on plastic material to assist in removing individual bags from the roll. A plastic film material is continuously fed into the machine where multiple servo axes are used to help perforate, seal and pull the material toward an exit station. A high-speed counter module is used to control the timing of the horizontal traversing and vertical cutter axes in order to accurately provide the seal and cut marks at the right locations on the material. A dancer arm is connected to an analog input toward the in-feed section of the machine to adjust the speed of the roll stock. Mitsubishi Electric’s advanced solution facilitates high-speed bag production of up to 300 bags/min.

4

Industry Solutions

Industry Solutions

Cut-to-Length Example Applications

Load-side Encoder

Induction Motor

Cut-to-length machines exist in a variety of industries to support applications including: • Bar feeders • Wood cutting • Sheet metal cutting • Wire cutting • PVC cutting

High-speed Inputs

RS485

RS422 GT1020-LBD FX3G

E710W

Overview Low cost cut-to-length applications cut raw material and are typically specified with variable frequency drives (VFDs) to drive an induction motor. The induction motor intermittently indexes the material at fixed length distances before each cut.

The challenging part involves monitoring feedback from an external load-side encoder using semi-robust fully-closed loop control to stop the motor accurately so that each part can be cut with the same length. An alternative, much less accurate solution uses a photoelectric sensor to detect the material’s edge so that the motor can decelerate for a coast to stop.

RFID Product Track and Trace Example Applications The application focuses on principles used in the following active tracking installations: • Automotive product assembly • Food and drink manufacturing • Postal package handling • Meat packing

Enterprise Level

Control Level (Mitsubishi) POW

CPU 0

Device Level/RFID (Balluff) 1

2

3

4

5

6

7

CC-Link (network)

Overview The combined RFID control solution from Mitsubishi Electric and Balluff provides advanced data tracking and error proofing that maximizes quality and increases the speed of production. The solution brings together Balluff’s extensive background in RFID communications and Mitsubishi Electric’s strong reputation in providing high performance control solutions.

CC-Link communication permits straightforward connection between the Balluff RFID processors and the Mitsubishi CPU. As CC-Link is an open network, the solution features simplified compatibility between multi-vendor products, enabling the creation of powerful control topologies. Furthermore track and trace data can be quickly expedited from the CPU to a central database via the MES-IT interface.

Industry Solutions

5

Industry Solutions

High-Speed Feeder (Single Axis) Example Applications Card feeder

High-speed feeder applications can be adapted to perform a variety of functions. Some of the example machine applications include: • Card feeding • Product/label placement • Mail sorting • Collating

Wait for yellow card, then feed pink card.

Mark sensor 1 Mark sensor 2

Continuous rotation

Encoder

Cards

GT12 GT16

MR-J3-B Safety

MR-J3-D01 I/O Card

Ethernet HF-SP / HF-KP GT10 MR-MQ100

Overview In high-speed feeder applications, separate pieces of material are fed by a servo motor to be placed in specific locations on a moving belt. The servo speed depends on the speed of the conveyor (external encoder) and is commanded to move intermittently depending on the timing of a sensor that detects an object or location for the feed material to be placed onto.

A second sensor detects the following card and establishes a precise stopping position. A synchronous encoder following function is used in combination with high speed registration.

High-Speed Feeder (Multi-Axis) Example Applications

Barcode reading

Feeder #1

Feeder #2 Presence/absence

• Stationary packaging • Cardstock packaging • Bulk mail • Paper collating

Sorter

Inserter Cards

Encoder

QJ61BT11N Q12DCCPU-V QX40 QY40P Q173D Q04UDEH Q173DPX GT16

E700 A7NC

MR-J3-B Safety

Overview An entire high-speed feeder application uses multiple servos to pass material along a conveyor belt to be collated and then inserted into envelopes, boxes, or other packages before being collected and sorted for distribution. In some feeder applications, a printing station may also be a part of the application. These types of machines are particularly useful in the Material Handling industry for the mass production of stationary goods, card packaging, and for the distribution of mass mail. Each feeder application requires synchronous start/stop servo movement in combination with encoder following and line shaft camming.

6

Industry Solutions

Industry Solutions

Winding Applications Free spinning roll

Example Applications Winder applications sit within a variety of different industries.

Examples are listed below: • Printing industry • Packaging industry • Paper industry • Wire drawing industry • Labeling industry

Drive reel & motor Free spinning roll

Web

Dancer & Potentiometer

GOT1000

700 Motor

Non–contact potentiometer A700

Overview There are two main types of wind applications – wind and unwind. Effective winding is carried out through monitoring and controlling the position of a dancer roll, and adaptive motor control. As fluctuations in the dancer position occur, the speed and torque of the motor are adjusted so that the web is wound/unwound cleanly without breakages.

Gantry Applications Example Applications

Safety light curtains

Z-axis Y-axis

Gantry applications sit within a variety of different industries.

Examples are listed below: • General material handling • Automotive assembly • Lathe loading • Machine tool loading • Aircraft assembly • CNC applications

X-axis Work piece

GT11 Handy

GOT Handy Machine tooling Material pick-up point

QD75MH4 Q02H

MR-J3-B MR-J3-B Safety Safety (x-axis) (y-axis) (x axis) (y axis)

MR-J3-B Safety (z-axis) (z axis)

Q Series Q12DCCPU-V

HF-SP

Overview A gantry is a positioning system that is used in material handling applications to move objects from point to point.

Application sizes can vary considerably, from small applications requiring movement of light materials with high speed repetition to much larger applications requiring movement of heavier loads.

Industry Solutions

7

Industry Solutions

Safety Solution Example Applications The application focuses on principles used in the following active tracking installations: • Automotive assembly • Food and drink manufacturing • Packaging • Storage and conveyors

GT12

Overview Effective machine safety is not only a moral obligation, but it is also often required by regulation to provide safe working environments for employees. When performed correctly and with the appropriate technology, safety can increase productivity and financial return along with protecting employees from injury.

Mitsubishi’s safety solution is vertically aligned to provide machine safety from the device layer to the control layer. With a complete portfolio of safety controllers and networks, and a partnership with SICK Safety Devices, Mitsubishi Electric is able to provide safety solutions for all applications, from stand-alone machines to large scale manufacturing lines.

Gapping and Indexing Applications Example Applications Gapping and Indexing conveyors are found typically within material handling applications.

• Package handling • Warehouse management • Food processing • Baggage handling

Barcode reader

Indexing conveyors and paddle diverters

Gapping conveyors

GT16

Gapping A700

A700

Indexing A700

A700

A700

A700

D700

D700

Conveyor motors

Paddle diverter motors

Optical sensors Scanner

Encoders

Overview

8

Industry Solutions

Gapping and indexing conveyors are used in material handling applications to move packages from point to point with high accuracy. Success in these applications is reliant on accurate reading of the conveyor encoders so that the package position is continuously monitored. In simple terms, the gapping conveyor provides sufficient spacing between products so the barcode scanner can read each code one package at a time. Sufficient spacing also improves the paddle diverter accuracy when moving packages to defined points.

Industry Solutions

Machine Tool – XYZ axes (Pulses/Analog command) Z axis

Example Applications

MR-ES series servomotors (up to 2kW)

• Milling machine • Lathe machine • Water cutter machine • Laser cutter machine • Electrical discharge machine

Y axis X axis

Pulse trains / Analog

MR-ES series servo amplifiers (up to 2kW)

Alternate solution: MR-J3A series servo amplifiers & motors M70 / 700 series CNC whole package

PC-based controller

Overview

(refer to www.meau.com)

In general machine tool applications have 3 axes of servo motors as X, Y and Z axes where a computer based controller controls the servo amplifiers with pulse-trains or analog output. The servo amplifiers have to control the servomotors with quick response, accuracy and smooth movements according to the commands.

M70 CNC Router Example Applications CNC gantry routers are used to cut a variety of materials including wood, plywood, MDF, plastics, foam, and other non-ferrous stock. Many industries use CNC gantry routers in applications such as: • Cabinetry • Furniture • Architectural millwork • Composites, including boats and surfboards • Musical instruments, especially guitars

A700 Vector Drive OP700 Operator Panel

M70 CNC

FCUA-DX121 Remote I/O FR-A7AP Encoder Interface

MDS-D-SVJ3 Junior Servo Drive HF Series Servo Motor

Spindle Motor

Overview A gantry router is a style of CNC milling machine that uses a pair of slaved servos on the X axis to move a gantry that carries the Y and Z axes. The open design allows for easy loading and unloading of large sheets of material. A vacuum hold-down system and spoil boards can make clamping unnecessary and allows for cutting nested parts. A dust collection system keeps the workspace clear of dust and chips.

Industry Solutions

9

Industry Solutions

Load Sharing Example Applications

Master Control Station Q12DCCPU-V Q03UD

Load sharing applications exist primarily in heavy industries where large loads need to be transported long distances.

Example applications include: • Long conveyor runs – aggregates, mining, and tunnel boring • Chain conveyors

GT16

QJ61BT11N

Q Series Slave Drives

ntrol

- Torque Co

A700 A700 Master Drive Speed Control

A700

A700

• Speed reference signal is sent to Master Drive • Torque reference from Master Drive is read by PLC • PLC uses PID algorithm to create torque reference to slaves • Simultaneous torque reference is sent to each slave drive

Overview A load sharing application is one where there are two or more motors mechanically connected to drive the same load. A good example of this is when controlling a long conveyor belt. In theory, if there are multiple motors that are all supplied by the same frequency, they will all output the same shaft speed and, since they are physically connected, they will all share the load evenly.

Pumping Applications Example Applications

Pump control room

Green house

Pumping applications sit within a variety of different industries.

Examples are listed below: • Waste water treatment • Building water management • Irrigation • Household water management

GOT1000 HMI

Fluid pressure sensor Pumping Packaged Solution

A700 VFD

Pump

Overview Pumping can be defined as the ability to compress or drive a fluid. Within applications, pumping can mean passing a fluid into or out of a system where either fluid pressure or flow rate is controlled. Typically an inverter operates at the center of the application determining the control characteristics of the pump.

10 Industry Solutions

Industry Solutions

Motion Alignment (X-Y-Ø) Example Applications

Vision Systems*1

Motion alignment machines can be used for a variety of applications including those for: • Pre/post inspection system imaging • Solar panel production • FPD manufacturing • 3D LCD manufacturing • SEMI logic inspection • Pre-alignment routines

Servo motor

Q170MCPU Ethernet

MR-J3-B

Servo motor HF-KP TM-RFM

VGA Adapter

Vision Systems *1)

GT16

Overview Combining servo control with vision system alignment for X-Y-Ø stage applications provides high-precision control to accurately correct positioning data on-the-fly. Unlike other systems, this solution does not require much time for calibration and it also guarantees a precise stopping position (1 micron accuracy) with incremental servo moves in order to assemble parts, apply material coating, or to align glass plates with polarized film. The vision systems in this application help to reduce the machine cycle time through using a larger field of view, and the motion controller’s built-in vision instructions also help to significantly reduce the time required for programming and troubleshooting.

Industry Solutions 11

Industry Solutions

Solar Tracking Control Example Applications The application focuses on principles used in the following active tracking installations: • Horizontal axis tracking • Vertical axis tracking • Polar tracking • Two axis mount tracking

GT10 HMI

D700 VFD FX3U PLC

FX3U-4AD

Solar Packaged Solution Option

Overview Solar panel tracking systems optimize energy output of photovoltaic panels by positioning them to follow the sun’s path throughout the day. The sun’s position in the sky varies both with installation location, the seasons, and the time of day.

Tracking systems are being used increasingly as purchasers of solar systems understand that the cost of energy over the life of the panel is more important than the initial installed cost per watt. Recently, the solar industry has been using Levelized Cost of Energy (LCoE) as the main measuring stick of solar power plant efficiency. This figure looks at all costs associated with a solar panel installation over its entire lifespan, including initial installed cost, degradation in panel efficiency over time, and on-going maintenance and trouble-shooting. Compared with fixed-position installations, solar tracking systems lower the LCoE of a solar panel installation, making solar a viable long-term option to other energy sources

12 Industry Solutions

Industry Solutions

Packaged Solutions Solar Tracking Example Applications Solar Packaged Solutions are available or can be configured for controlling the following types of tracking applications: • Horizontal Single Axis Tracker (HSAT) • Vertical Single Axis Tracker (VSAT) • Tilted Single Axis Tracker (TSAT) • Tip-Tilt Dual Axis Tracker (TTDAT) • Azimuth-Altitude Dual Axis Tracker (AADAT) Tracking Controller (TC) Using Mitsubishi FX Series UL508 Enclosure NEMA 4 Rated 480VAC Power Supply 120VAC (1Ф) (1Ф)

Transformer

Ethernet Module

Breaker AC TB

Actuator Motor Controller (AMC)

Using 1 hp VFD D740 UL508 Enclosure NEMA 4

Power Circuit

Actuator Motor Controller (AMC)

Using 1 hp VFD D740 UL508 Enclosure NEMA 4

FX3U-16MR/ES

Up to 25 Total Remote Stations in a Network

Signal TB

Power

Power

C/B

C/B

Cat5e RS-485 Communication Up to 500m

480VAC (3Φ) Input Mains Power Supply

AC TB

Signal TB

2 Limit Switches & 24VDC Supply

3-ph TB

AC TB

Signal TB

3-ph TB

2 Limit Switches & 24VDC Supply

Recommended MicroMAX™ Inverter Duty Motors

Overview Two of the biggest concerns for setting up a solar farm are the cost of installation and operating overheads. To overcome these issues Mitsubishi Electric has developed a complete Packaged Solution for solar tracking that reduces design time, provides a simple method of installation and minimizes the total cost of ownership for the end user. Mitsubishi Electric’s solar tracking solutions are not only designed to cope with the harsh environments at installation sites, but they also provide high accuracy array control and allow users to monitor and control the array position both locally and remotely

Industry Solutions 13

Controllers PLC Overview

16-4096 I/O

Q Platform Q Series / iQ 24-4096 I/O

P E R F ORMANCE

L Series 16-3 I/O 16-384

X33U/FX3UC U FX3U/FX3UC 3G G FX3G FX1S S HA2 HA A ALPHA2

14-256 I/O 14-256 10-34 I/O 6-28 I/O

EXPANDABILITY EX

Mitsubishi Electric’s controller line is one of the widest in the industry. Our offering spans from our Alpha2 Simple Application Controller with as little as six I/O points, all the way to the high-end iQ Platform capable of running entire plants.

• Alpha2 Simple Application Controller: Aimed at very low end applications where a traditional PLC is not required. Alpha2 offers some unique capabilities, such as high current relays, a built-in HMI, real time clock, AS-i networking, and an innovative graphical programming system.

• FX3 SuperMicro Family: The FX3 Series PLC provides extremely cost effective control for low to mid-level control applications. FX PLCs are easy to specify because the inputs, outputs, control CPU, and power supply are integrated into one unit. With more than 10 million PLCs sold, the FX Series PLC is the world leader in compact PLC solutions.

• L Series: The newest controller platform that combines performance, functionality and flexibility in a modular rack-less design. Equipped with industry proven sequence control technology, the L Series improves machine design and control by adding large memory capacity, onboard I/O,

14 PLC Overview

Ethernet, CC-Link, high speed motion capabilities and a multi-language backlit message display. This control platform is ideal for the OEM machine builder that is serious about delivering a modular cost effective solution for midrange control requirements.

• Q Series/iQ Platform: The future of automation. The iQ Platform integrates four main disciplines of control; sequence, motion, robot and CNC, onto a single back plane. The Q Series represents the current state of the art controller technology, and remains the platform of choice for a wide variety of applications from individual machines to entire plants.

Our controllers are complemented by a comprehensive array of software tools and networking technologies, including leading edge open technologies such as CC-Link. Offering seamless integration to our other automation products such as VFDs, motion control and HMIs, they provide a comprehensive solution with the controller at the center.

Controllers Alpha2

DID YOU KNOW? The Mitsubishi Electric Alpha2 controllers can display information in bar graph form.

Alpha2 controllers are designed to provide easy, flexible and powerful control that is rugged enough for the factory floor, and easy enough to use at home.

Alpha2 Base Units • 10, 14 and 24 I/O models • AC inputs on AC powered units • Analog/digital selectable inputs on DC powered units • Powerful display • Front panel editing

Alpha2 Extension Cards • 4 digital 24VDC inputs with integrated 1KHz counters • 4 digital 240V AC/DC inputs • 4 relay outputs • 4 transistor outputs • 2 analog outputs (0-10V/4-20mA) • Program memory for up to 200 function blocks • AS-i communication capability • Modem connectivity • Outdoor applications down to -25°C

The Alpha2 is ideal for the following types of applications: • Greenhouses and agriculture • Pump controllers • Handling systems • Door, gate and window controllers • Special-purpose vehicles • Heating, AC and ventilation • Lighting systems • Alarm and security systems • Outdoor applications

Visual Logic Software • Graphical software • Function block programming • Simulation function • Visualization tools

Temperature Input Adapters • 2 channel thermocouple input • 2 channel PT sensor input • Connect up to 4 adapters per base unit

Alpha2 15

Controllers FX Series

DID YOU KNOW? Mitsubishi Electric has sold over 10 million FX CPUs.

The FX “SuperMicroTM” is a brick style PLC with power supply, CPU, programming memory, and I/O included in the same package. From the smallest model, the FX SuperMicros have built-in positioning commands, high-speed counters, extensive memory, optional analog modules, networking capability, and transistor or relay outputs.

FX1S – Keeping it Simple • Main Unit I/O: 10/14/20/30 points • Controllable I/O: 10 - 30 points (34 with FX1N-4EX-BD) • Ample memory capacity (2000 steps) and device ranges • Built-in high speed processing and positioning • Integrated real-time clock and scheduling • Increased functionality using expansion boards and special adapters FX3G – Customized Control Main Unit I/O: 14/24/40/60 points • Controllable I/O: 14 - 256 points (with CC-Link remote I/O) • Highly flexible and expandable CPU • Dual bus architecture with 32k steps of internal program memory • Integrated real-time clock and scheduling • Exchangeable communication expansion boards that mount directly into the main unit (RS-232C, RS-422, RS-485) • Two built-in variable analog potentiometers available for adjusting the timer set time FX3U – Top of the Line • Main Unit I/O: 16/32/48/64/80/128 points • Controllable I/O: 16 - 384 points (with CC-Link remote I/O) • Expandable CPU with increased speed, performance, memory and all new functions • Dual bus architecture with 64k steps of internal program memory • Built-in high speed processing and positioning • Integrated real-time clock and scheduling • Interchangeable communication option boards (USB, RS-232, RS-422, RS-485) and ADP (communications, analog, temperature, high speed I/O, etc.)

• Easy programming with large instruction set and table positioning configuration FX3UC – Slim Fit • Main Unit I/O: 16/32/64/96 points • Controllable I/O: 16 - 384 points (with CC-Link remote I/O) • Ultra-compact CPU size with connector type I/O • Expandable CPU with increased speed, performance, memory and all new functions • Dual bus architecture with 64k steps of internal program memory • Built-in high speed processing and positioning

16 FX Series

Controllers FX Expansion Options

FX Expansion Options Unpowered I/O Expansion • 8/16/32 I/O • AC or DC input • Relay, transistor and triac outputs Powered I/O Expansion • 32/48 I/O • AC or DC powered, AC or DC input • Relay and transistor (sink/source) outputs Special Function Modules (SFM) Analog • 2/4/8 channels • Input, output and mixed (in/out) formats • 12/15 bit resolution Temperature Control • 2/4 channels • Thermocouple, Pt100, Pt1000/Ni1000 input Communication • RS-232 interface Networks • Ethernet and Open Fieldbus connections (CC-Link, DeviceNet and Profibus) Positioning • Single and dual axis • Electronic cam module High Speed Counter • Single and dual channel high speed input

Special Adapter (ADP) Analog • 4 channels • Input, output and mixed (in/out) formats Temperature Control • 4 channel • Thermocouple, Pt100, Pt1000/Ni1000 input Communication • RS-232 or RS-485 • Modbus master/slave Positioning • Single channel high speed output • High speed counter • 4 channel high speed input Data Storage • Compact Flash interface Expansion Board (BD) Analog • Dual channel input or single channel output Communication • RS-232, RS-485, RS-422 and USB Analog Setpoint • 8 input points

FX Expansion Options 17

Controllers L Series

DID YOU KNOW? The integrated display unit performs many useful functions including CPU monitoring and test functions. The display is also capable of displaying CPU status, system and user error messages in multiple languages. Finally, the display backlight can be programmed for green or red operations.

The L Series is a powerful but compact modular controller with many features built-in to the CPU itself. The rack-free design promotes high system flexibility with minimum form factor. Built-in Mini-B USB and Ethernet allow for easy communication, along with a built-in SD/SDHC memory slot for data logging and memory storage, and built-in digital I/O for simple high-speed counting and positioning functions. The high-performance version CPU also includes a built-in CC-Link interface for master/local station networking. This highly flexible architecture makes the L Series ideal for both stand-alone and networked machines.

Power Supply Module

CPU Module

Memory Card Display Module

18 L Series

I/O, Intelligent Function Modules

End Cap

Controllers L Series

Key features include:

Master Station

Local Station

Local Station

• Flexible rack-free modular design • All-in-one CPU with built-in Ethernet, and positioning I/O functions • Up to 260K step memory • As low as 9.5ns instruction processing • 24 points of built-in I/O • Built-in data logging capabilities • Commonly available SD/SDHC memory media • Expansion capabilities for I/O, analog, communication, and motion/positioning • Integration into iQ Works and GX Works2 next generation software • Main Unit I/O: 16/32/64/96 points • Controllable I/O: 16 - 384 points (with CC-Link remote I/O) • Ultra-compact CPU size with connector type I/O • Expandable CPU with increased speed, performance, memory and all new functions • Dual bus architecture with 64k steps of internal program memory • Built-in high speed processing and positioning

L Series 19

Controllers Q Series/iQ Platform

DID YOU KNOW? Mitsubishi Electric is one of the world’s leading suppliers of PLC systems. We have supplied in excess of 10 million systems during the more than 30 years we have been in the business.

With the Q Series, Mitsubishi Electric originated the controller class now recognized as the PAC (Programmable Automation Controller). This multi-disciplinary automation platform addresses the needs of both end users and OEMs, scalable from small stand-alone machines to entire plants, across a broad range of industries. The Q Series offers a broad spectrum of automation capabilities, including process/redundant, motion and PC based control functions in addition to traditional sequence control. These functions can be mixed and matched within the system to address the exact needs of your application. The Q Series family also includes the QS Safety PLC. The QS is a fully certified machine safety solution that provides critical protection to plant personnel from machinery hazards. It provides a cost effective safety solution by operating all safety devices over the open CC-Link Safety device level network, thus avoiding costly discrete wiring. The QS meets all industry standards, including SIL 3 and Category 4, and is easy to integrate with Q Series systems for a complete solution.

In 2008, Mitsubishi Electric introduced the iQ Platform, a groundbreaking step forward in automation systems. It is a culmination of Mitsubishi Electric’s industry-leading core technologies, including the world’s fastest Q Series sequence controller, unmatched high-precision and high-speed QD motion over fiber-optic SSCNETIII, high-resolution mill or lathe C70 CNC, and low-payload high-performance SQ robot control. Furthermore, implementing Mitsubishi Electric’s own e-F@ctory initiative, information systems and databases can be connected directly to manufacturing assets using the MES Interface IT, providing an efficient and reliable solution to complete facility integration. The end result is a truly universal platform for all manufacturing.

Sequence Control CNC Control

Motion Control Robot Control

Ethernet

20 Q Series/iQ Platform

Controllers Q Series/iQ Platform

Enterprise level system

GX Developer 3rd party software (SCADA, data logger, etc.)

CC-Link IE or MELSECNET/H PCI board

Ethernet Controller Network or MELSECNET/H Controller Network

Redundant system Standby system

Control system Tracking cable

MELSECNET/H Remote I/O

Station 2

Station 64 Redundant power supply extension base

Key features include: • Large selection of CPU types from entry level, to high-capacity high-performance with built-in Ethernet, to dedicated Redundant or Safety • Multiple CPU support on a single back-plane rack, with fast and easy data transfer between • Industry’s fastest processing speeds with basic execution at 9.5ns per instruction • Up to 96 axes of high-speed high-precision motion control integrated on the same rack as the sequence control CPU, using SSCNETIII fiber optic servo network • Direct Mitsubishi Electric Vertical or SCARA Robot controller integration; 3 max • Direct CNC controller integration; 2 max for a total of 32 axes and 14 individual parts programs • Standalone PC or C Language CPU for fully PC-based control applications • Redundant CPU option offers maximum process reliability for zero downtime requirements • Multi-program capabilities allow for concurrent development, code reuse, better program organization, and faster troubleshooting for less downtime • Dedicated easy-configuration software included in programming software for intelligent function module setup • Data logging, direct database communication, and web server e-F@ctory expansion options • Network speeds up to 1Gbit Ethernet and support for open networks such as CC-Link, Modbus, DeviceNet, and Profibus • Fully customizable expansion with digital I/O, analog I/O, temperature control, motion, positioning, serial communication, and networking • Compact size saves panel and enclosure costs

Q Series/iQ Platform 21

Controllers Automation Networks

Control

Enterprise

Mitsubishi Electric supports a wide variety of network systems and technologies across our automation solution portfolio. From enterprise to sensor level, Mitsubishi Electric can work with you to provide an effective solution to your application.

Max. 1 Gbit/s

C ontrol

Sensor

Device

F ield

22 Automation Networks

/

Safety

Controllers Automation Networks

Enterprise Level • Use the iQ Platform, Q Series, or FX3 Series controllers’ Ethernet connectivity options as a bridge to upper level enterprise “front office” functions from plant floor networks. This includes Peer-to-Peer communication, FTP server/ client, E-mail, Webserver, and 3rd party software interaction.

• Leverage existing LAN/WAN and Internet infrastructure to extract plant floor data for use anywhere in your organization or anywhere in the world with appropriate security measures.

• Easily share vital shop-floor controller information with high level IT systems directly with no intermediate PC or middleware via innovative MES interface capability.

• Supported networks: Ethernet 100base-T, 10base-T, 10base-5, 10base-2 (TCP/IP, UDP/IP, MELSEC Communication MC Protocol) Control Level • Connect multiple automation cells or separate lines together using control level networking.

• CC-Link IE Control introduces industry-leading 1Gigabit Ethernet over dual-loop fiber technology for nearly unlimited bandwidth and unmatched deterministic data transmission.

• Coordinate plant floor operations at the controller level without the need for higher level supervisory control.

• Enable maintenance personnel to access controller programs and data anywhere on a shop floor via network access.

• Guaranteed operation through power outage, system error, or hardware damage using Redundant Systems.

• Supported networks: CC-Link IE Control, Ethernet, FL-Net, Modbus/TCP, MELSECNET/H Device Level • Within a machine, system or line, link a wide variety of automation devices to a controller by using a network.

• CC-Link IE Field brings easy Cat5e and RJ45 wiring to deterministic 1Gigabit Ethernet Remote I/O and Intelligent Function Module control.

• Eliminate costly wiring harnesses by replacing multiple wiring runs with one simple cable.

• Integrate HMIs, VFDs, controllers, I/O and 3rd party products on the same network.

• Improve system performance by increasing controller to device communication speeds and adding diagnostic information.

• Supported networks: CC-Link IE Field, CC-Link, CC-Link Safety, Modbus/TCP, Modbus/RTU, Profibus-DP, DeviceNet Sensor Level • Apply device level network benefits to simple I/O • Connect I/O with dedicated connectors and cables • Supported networks: CC-Link/LT, AS-i

Automation Networks 23

Motion Servo Amplifiers and Motors DID YOU KNOW? MR-J3 is one of the “World’s fastest” servo series with a speed frequency response of 2100HZ.

Offering a capacity range of 50W to 55kW, a high resolution 262,144ppr encoder mounted as standard to provide stability even at low speeds and an ever-evolving automatic tuning function that makes precise tuning easy. The MR-J3’s high torque motors can operate at up to 6000rpm, and have a speed frequency response of 2100Hz. Set-up, diagnostics, and tuning are easy, thanks to MR-Configurator, a Windows™ based software package with many diagnostic functions, such as an advanced machine analyzer, software oscilloscope, and high-speed monitor. A parameter setting window makes start-up easy, and a USB interface enables high-speed sampling and long-term wavelength measurement. MR-J3 supports position, speed, torque, SSCNETIII network, CC-Link, RS-485 multi-drop and now turret index control methods.

MR-J3-A Series - General Purpose Interface • Multiple control mode; speed, position and torque • Up to 1Mpps pulse train input • Up to 6000rpm motors • Advanced real time auto-tuning features • 100~120VAC, 200~230VAC and 380~480VAC models

MR-J3-B/J3-B Safety Series – SSCNETIII High Speed Interface • Up to 2100Hz speed frequency response time • SSCNETIII compatible (50Mbps) • Automatic vibration suppression • Capacities from 50W up to 55kW • STO and SS1 functions available *

MR-J3-A

*Not available with MR-J3-B amplifiers

MR-J3-B Safety

MR-J3-T Series – Built-in CC-Link/CC-Link IE Positioning Function • Perform positioning by setting position data, motor speed, accel and decel in point tables (255 points can be stored) • Ideal for simple single-axis positioning applications • Speed up to 1Gbps with CC-Link IE Option module MR-J3-T

24 Servo Systems

Motion Servo Amplifiers and Motors

DID YOU KNOW? Mitsubishi Electric was the first to introduce auto-tuning in 1993 and continues to be the leader in real-time auto-tuning technology.

MR-E Super Servo Amplifiers – Pulse Train Positioning/ Analog Speed-Torque With even higher positioning accuracy and responsiveness, the MR-E Super is an excellent choice for applications ranging from 100W to 2kW. It is available in pulse-train position or analog speed/torque control models and features Mitsubishi Electric’s legendary auto-tuning and vibration suppression functions while utilizing 500Hz analog frequency response and accepting pulse commands up to 1000 kHz. The motors are low to medium inertia up to 4500rpm and are equipped with a higher resolution 131,072ppr encoder. Set-up and diagnosis is easy with the MR-Configurator Windows based software.

• Low cost servo for simple applications • Advanced real time auto-tuning features • 200~230VAC models • Capacities from 100W up to 2kW

MR-E Super

MR-JN Servo Amplifiers – Servo Solution to Stepper Motors The MR-JN is a small, high performance, reliable servo series that is a perfect replacement for existing stepper motor systems. It saves you time and money by tuning your machine in a matter of minutes, with a simple press of a button. With its Built-in positioning function, Advanced Vibration suppression control and the ability to prevent resonance as a machine ages, it is one tough servo series.

• Up to 1Mpps pulse train input • Up to 4500rpm motors • High resolution encoders – up to 132072 pulses per revolution • One touch Auto tuning button

MR-JN

Servo Systems 25

Motion Servo Amplifiers and Motors

Rotary Servo Motor Series Utilizing the most advanced concentrated winding techniques and latest technology, our brushless rotary servo motors are among the most compact in the market. Mitsubishi Servo Motors offer a wide range of power, speed and inertia ratings providing a motor for all applications.

Ranging from 50W through 55kW, all motors are fitted with absolute encoders as standard. Therefore, an absolute system can be created by simply providing power to Servo amplifier via a battery. Once this has been done the backup battery allows the Servo motor position to be constantly monitored, even when disconnected from power.

• Eight different models available • Models range from 50W~55kW • Up to 6000 rpm motors • High speed – high torque motors • Up to IP67 rating motors

Linear Servo Motor Series When extreme high speed and accuracy is essential for your application, Mitsubishi’s linear servos are the perfect solution. With 17 core type (liquid cooled) models ranging from 60N to 18000N and 9 coreless types in the range of 50N to 3200N, our linear servo technology offers high power density in a compact package, improved heat dissipation, and extremely smooth motion. Designed for easy-of-use, our motors seamlessly integrate with our MR-J3 amplifiers allowing for seamless start up and faster project development as well as a “Robust Disturbance compensation function” that suppresses offset disturbances that cause uneven speeds.

• Direct drive linear servomotors with multiple models to choose from • Attain high-speed operations of up to 2m/s • Compatible with MR-J3-B-RJ004 amplifiers • Robust disturbance compensation suppresses uneven speeds from the machine side resulting in constant speed with higher accuracy

Direct Drive Motors (DDM) Mitsubishi’s direct drive motors have been designed as an enhancement to the MR-J3 series. Currently, we offer 12 types of motors with an instantaneous maximum torque range from 6Nm to 720Nm and an outer diameter of ø130mm to ø330mm. The very high 1,048,576 pulse per revolution encoder allows for extreme accuracy and since the load is directly coupled to the direct drive motor, gear reducers and transmission elements are not needed, resulting in higher torque and rigidity. The motor’s low profile design allows for compact construction and a low center of gravity enhances machine stability.

• The Industry’s smallest and flattest direct drive motors • Available in both Framed and Built-in types • High precision positioning with built-in high resolution encoder

26 Servo Systems

Motion Pulse Train Positioning

DID YOU KNOW? All FX PLCs can communicate directly to Mitsubishi Electric servos via Pulse Train Outputs.

FX3U-2HSY-ADP FX3U-4HSX-ADP

FX3U-CNV-BD FX3U-16M

FX3U-2HC GT1155

Servo 1

Motor

Ser Servo rvo 2

Motor

Ser Servo rvo 3

Motor

The FX Series of PLCs feature built-in high-speed outputs that can be used to control the Mitsubishi Electric MR-J3 Series of servo amplifiers. This solution is extremely cost effective for high precision/low speed or high-speed/low precision applications. All FX Series PLCs also contain high-speed counters that can be used to read 1-phase or 2-phase (quadrature) encoders to verify position data. For higher speed pulse train control or more difficult motion profiles, Mitsubishi Electric provides various special function modules that provide the functionality and price point to meet your needs.

FX1S • Up to 2 axes of built-in positioning • 100kHz maximum simultaneous outputs • Dedicated motion instructions

FX3G • Up to 3 axes of built-in positioning • 100kHz maximum simultaneous outputs • Dedicated motion instructions and table operation • CC-Link Network connectivity to control additional motion products

FX3U/FX3UC • Up to 3 axes of built-in positioning from base CPU or up to 4 axes of positioning with high-speed output ADPs (FX3U) • 100kHz maximum simultaneous outputs or up to 200kHz with high-speed output ADPs (FX3U) • Dedicated motion instructions and table operation • CC-Link Network connectivity to control additional motion products

FX2N-1PG-E • Single axis positioning with 100kHz maximum output frequency • Up to 8 modules per expandable FX3U/FX3UC CPU

FX2N-10PG • Single axis positioning with 1MHz maximum output frequency • Single and multiple speeds, interrupt and table operations • Up to 8 modules per expandable FX3U/FX3UC CPU

FX3U-20SSC-H • Dual axis positioning with linear and circular interpolation • 50Mbps fiber optic connection – SSCNETIII • Simple software utility for configuration, monitoring and debugging • Up to 8 modules per expandable FX3U/FX3UC CPU

FX3U-2HSY-ADP • Dual axis high speed positioning • 200kHz maximum frequency • Up to 2 high speed output ADP interfaces per expandable FX3U/FX3UC CPU

Pulse Train 27

Motion Single-Axis Motion Controller

MR-MQ100 Single-Axis Motion Controller

MR-J3-B

MQ100

The MR-MQ100 is designed to be the performance leader for single axis and 1.5 axis control. Combined with the speed and accuracy of the SSCNETIII fiber optic communication network as well as the power of the MR-J3-B safety series servo amplifiers, machines can now perform at higher production levels where applications involving rotary cut, flying saw, labeling operation and other high speed applications are required. Intuitive software makes implementation of encoder following, CAM profiles, registration mark synchronization and even servo axis tuning very easy and quick.

• Industry’s leading single/1.5 axis motion controller • Digital I/P:20, digital O/P:18, analog I/P: 2 and analog O/P: 2 available • High speed registration, camming, external encoder following and line shaft • Built-in serial port and Ethernet for GOT connections • Interface with Ethernet I/P available • AOI functions are available for third-party PLC • For simple and small size complex machines

Q170MCPU Stand-Alone Motion Controller The Q170MCPU motion controller completely fills the need for a stand-alone unit with built-in motion and logic control. The development concept is based on a compact unit with built-in power supply, motion and logic control, Ethernet network, external encoder interface and high speed registration inputs enabling OEM’s to design a high-performance system in a more compact footprint. The Q170MCPU also has the ability to be easily integrated into 3rd party control platforms by utilizing the built-in Ethernet network and auxiliary gateway modules such as the ETH-1000 Ethernet IP gateway. It has a very high performance motion CPU equivalent to our iQ Platform motion CPU the Q172D and can be connected to our MR-J3-B Series servos over Mitsubishi Electric’s servo system control network (SSCNETIII).

• One axis to 16 axis built-in stand-alone motion controller • Built-in powerful PLC and Motion CPUs in one unit • Built-in Serial/USB/Ethernet communication protocols • High speed registration, camming, external encoder following and line shaft • 512 digital I/O, analog modules, network modules available • Interface with Ethernet I/P available • AOI functions are available for third-party PLC • For mid-size and high end simple and complex machines

28 Single-Axis Motion Controller

USB or

Ethernet

RS-232C GX Developer

Memory Card

MT Works

Extension cable SSCNETIII

Extension base unit with various Q Series modules

MR-J3-B MR-J3W Servo 2 axis Servo

Incremental synchronous encoder

Extension cable GOT

Motion Q Series Multi-Axis Motion Controllers

DID YOU KNOW? Mitsubishi Electric has an installation base of over 1.5 million axes using SSCNET – one of the largest motion network installed bases in the world!

Mitsubishi Electric’s Servo System Control NETwork is a robust digital network dedicated to motion control. SSCNETIII not only provides precise coordinated motion control for up to 32 axes per CPU, but also allows for real-time servo monitoring and diagnostics. SSCNETIII is the proven choice for motion applications of all complexities.

Q172D and Q173D Motion CPUs • Combines the power and flexibility of the multi-CPU iQ Platform • Ideal for applications with electronic line-shafting, camming, high-speed registration and following • 8 or 32 axis modules can be combined for applications of up to 96 axes of motion • Powerful software tools provide the flexibility to tackle any application • SSCNETIII provides the performance and axis synchronization required for high production machinery • A strong foundation for a single-source automation solution

QD75MH Positioning Modules • Shares the power of the iQ Platform and Q Series • Capable of point-to-point positioning, 3-axis linear and 2-axis circular interpolation • User friendly software for programming and setup • Available in 1, 2, or 4 axis models • Multiple QD75MH modules can be combined with a single Q CPU • Real time diagnostic and monitoring data

Q Series Motion Controllers 29

Drives Variable Frequency Drives

DID YOU KNOW? Mitsubishi Electric is the first drive manufacturer, and perhaps the only, to achieve 12 million in unit sales and continues to manufacture over 1 million units annually.

Output Waveform Energy Saving • Mitsubishi Electric drives have class-leading technology to save energy in pump and fan control. Perfect for either industrial or commercial applications.

• The F700 VFD maximizes efficiency by calculating the ideal output voltage for any motor load.

Flexible/Versatile Mitsubishi Electric Product

• Drives available in all sizes from fractional horsepower to 1000 HP • 120, 240, 480 and 600V drives are all available • Any VFD can be engineered into custom packaged solutions on request • A product for any job from the simplest to the most demanding

Simple Operation • All drives share common parameter sets and terminal markings • All drives can communicate together on the same RS-485 network • All programming tools can be shared across ranges and series • Wearing parts, such as fans, can be easily replaced in the field Competitor Product

Unparalleled Quality and Reliability • Mitsubishi Electric drives are designed for 10 years of maintenance free operation – even in harsh environments • Regularly trusted in site-critical applications by some of the world’s most important companies

Dynamic Performance • As well as general speed control, Mitsubishi Electric has drive solutions for positioning, tension or speed control. A full range of regenerative options allow for straightforward replacement of DC systems.

• Anything that a 3-phase motor can do, Mitsubishi Electric has the answer

Field Bus Capability

A700 Speed Torque Chart

30 Drives

• Includes Profibus-DP, LonWorks, CC-Link, DeviceNet, Modbus RTU, Metasys N2, Siemens FLN, Ethernet/IP, Modbus TCP/IP, ControlNet, BACnet, Can-Open and Profinet

Drives

Variable Frequency Drives

D700 Series - Low cost micro VFD with Mitsubishi Electric quality • Digital setting dial with integrated display making configuration fast and easy • Built-in Safety Stop Function (STO) compliant with EN954-1 • Open loop flux vector control allows 60:1 speed range • Advanced functionality for fan and pump control • Low cost and Mitsubishi Electric quality ensure solid solutions

E700 Series - The cost-effective variable speed control solution for general

5 YEAR

WARRANTY

D700

purpose applications • Advanced magnetic flux vector control with auto-tuning • Available built-in Safety Stop Function (STO) compliant with EN954-1 • Selectable cooling fan operation mode • Built-in PID control • 120:1 speed range • Brake transistor as standard • Remote I/O capability • RS-485 communications as standard (Mitsubishi or Modbus RTU)

F700 Series - Built to optimize 3-phase motor control

5 YEAR

WARRANTY

E700

• Bi-directional coasting motor restart • Built-in PLC allows user customization - maximum flexibility • NEMA 1 UL Type 1 enclosure designs • FR-DU07 programming dial and set-up software • Built-in EMC filter • Upgrade of energy optimization control • Control terminals can be used over a network as remote I/O • UL listed for single phase input • Dedicated pump control functionality with improved usability

A700 Series - Intelligent programmable drive for effortless control of the

F700

most demanding of loads • Built-in PLC allows user customization - maximum flexibility • Mitsubishi Electric’s RSV technology ensures class-leading dynamic performance – driving or overhauling • Dynamic braking circuit up to 30 HP • Performs speed, torque or positioning control • 200:1 speed range • USB port allows quick and simple commissioning with set-up software

A700

Drives 31

Packaged Solutions

Mitsubishi Electric Packaged Solutions provide value added custom engineered solutions that exceed customer’s expectations for quality, price, and performance. Each system is engineered and built to UL508A standards and factory tested before shipping. A complete AutoCAD documentation package accompanies every order. VFDs, PLCs, HMIs, Servos, and more can be mounted and wired inside any NEMA rated cabinet. Standard deliveries are 4 to 6 weeks.

Products include: • Pow-R-Gate HVAC II drives • 18 Pulse drives • Irrigation pump drives • Conveyor drives • Conduit adapter • Soft start pump drives • NEMA 12 and 3R cabinets • PLC and HMI cabinets • Heat sink out the back drives • Solar control cabinets Options: Circuit breakers, fused disconnect switches, reactors, matrix filters, communications cards, encoders, DB, AC line regeneration, common DC bus, speed, torque, position regulators, transformers, any NEMA rated cabinet wall or floor mounted, safety hardware, networks, and multiplexing Products: 6 and 18 pulse, bypass, non-bypass, soft start bypass VFDs, PLCs, HMIs, servos, networks, and computers all engineered and drafted using AutoCAD Application Engineering: Support evaluating customer specifications, technical assistance, and the latest package designs Enclosures: Wall, floor, NEMA 1, 3R, 4, 4X, 12, 12 ventilated, air conditioned, heat sink out the back, single or multi-bay, and operator control stations Manufacturing: Manufactured to UL508A standards, UL, cUL with CSA and CE standards available. Customer approval drawings issued for each order.

Factory Testing: All packaged solutions are tested prior to shipping. Witnessed combination tests are also available for special customer requests.

Project Management: Experienced engineers to manage projects from quote through startup Warranty: Standard two year warranty on every packaged solution Repeat Orders: Engineer once and manufacture many times to save money Demos: Any style demo unit to meet your needs

32 Packaged Solutions

Low Voltage Switchgear

Mitsubishi Electric WS Series Molded Case Circuit Breakers Designed to compliment Mitsubishi Electric VFD, motor control and servo products, the WS Series also has SCCR coordination with Mitsubishi Electric contactors and starters. Interrupt capacities from 10kA up to 100kA are available depending on customer need and the type of breaker. The range includes 9 different frame sizes with continuous current ratings from 5A up to 600A - suitable for 230V, 480V or 600V operation.

Main features: • UL489/CSA approved and tested - for branch circuit protection • Compact, reliable and cost effective • Suitable for isolation duty • Suitable for reverse connection • Suitable for AC or DC operation • TUV and CCC type approved, CE marked throughout the range • Fully RoHS compliant

Mitsubishi Electric S-N Series Contactors and Motor Starters A complete lineup of motor controllers to 800A in size. Products are UL and CSA approved as well as meet the standards of all major markets around the world. A full range of options and accessories are also available. Mitsubishi Electric contactors have been tested with the WS Series circuit breakers to provide the best possible panel SCCR ratings when used in combination.

Main features: • Patented CAN terminal design for simplified wiring • Simple removable arc covers for easy inspection • CX type finger protection terminals for increased safety • Advanced arc space design gives a very compact frame size • DIN-Rail mountable up to 35Amp frame size

Low Voltage Switchgear 33

Human Machine Interfaces GOT1000

The GOT1000 is the only HMI to combine both a 64-bit RISC processor and a highly advanced Mitsubishi Graphics Accelerator (MGA). The GOT1000 is the first HMI in the industry to embed preventative maintenance in an HMI and offer a front mounted USB port on most displays.

Mitsubishi Electric’s Graphical Operator Terminals (GOT) offer superior performance and reliability that is often the benchmark for product excellence and reliability. They offer the broadest and best mix of features, flexibility, quality and dependability. A wide range of terminal display options are offered, including traditional panel mounted and hand held formats. The configuration software is among the best in the world and offers unmatched power and flexibility while minimizing effort. To maximize developmental efforts, hundreds of seamless connections to many automation products are offered, as well as support for a wide range of automation manufacturers to easily satisfy any HMI requirement.

GOT1000 Hardware Features: Front panel mounted USB port • Compact Flash expansion slot • Communication option slots (built-in communication ports for GT10 and GT11 series) • 64bit RISC processor combined with Mitsubishi Electric graphics accelerator for high-speed processing and lightning quick touch operations and data crunching • Expandable project memory and upgradeable OS

GOT1000 Terminal Features Include: • Multi-channel connections: simultaneous communications to several devices • Scripting functions allow terminals the ability to run aux codes • Highly advanced alarm, messaging and recipe management • Multi-language (Unicode 2.1) and True Type font support (64K colors available on most models) • Multilevel security protection (device, screen, system and project levels) • Advanced data sharing and gateway functions (FTP, email, client/server functions and MES capabilities) • Highly advanced maintenance, preventative maintenance and diagnostics

34 Human Machine Interfaces

Human Machine Interfaces GOT1000

GT16 Series: The flagship GOT. Ideal for any stand-alone or networked solution, the GT16 easily delivers visualization for machine, factory and enterprise level applications. Unmatched in performance, the GT16 integrates both Multimedia (Video and Sound) and HMI functionality in a single platform. Unique to GT16 and GT15 Series are an assortment of embedded maintenance functions to improve uptime and operations.

GT12 Series: An extension of Mitsubishi Electric’s 4th generation line of GOTs. The GT12 includes many embedded maintenance functions and shares a lot of commonality with the GT16 and GT11 Series. The GT12 Series is designed primarily for connections to Mitsubishi Solutions. Terminals in this range deliver visualization on a budget for many machine and factory level applications. Models in this series range in size from 8.4 inch to 10.4 inch and offer a 256 color TFT display as standard.

GT11 Series: A mid level GOT. Ideal for many stand-alone machine level applications, these models build on the functionality found in the GT10 Series and add enhancements like scripting, animation and removable memory access (Compact Flash). Models are available in either panel mount or pendent style configurations.

GT10 Series: An entry level GOT. Ideal for many stand-alone machine level applications these models feature a host of high-end functions desirable by many machine builders and users. Models in this range are the smallest and most compact terminals in the lineup. Unique to the GT10 are models that offer a programmable multicolor backlit display that can easily communicate machine status to any type operator.

SoftGOT1000: A software based HMI solution. Ideal for any stand-alone or networked solution, SOFTGOT1000 easily delivers visualization for machine and factory level applications. This visualization package provides most of the functionality found in our popular hardware based solutions but runs on a personal computer.

Human Machine Interfaces 35

DID YOU KNOW? MELSOFT Software is used throughout the lifecyle of the hardware, from development, to commissioning, to maintenance.

iQ Works MELSOFT Navigator

iQ Platform

GX Works2 MT Works2 GT Works3 MX MES IT

Redundant Process CPU

Redundant Process CPU

GX Developer

GX Configurator

CNC MITSUBISHI

FX GX Developer

GX Works2

NC Configurator NC Monitor NC Designer NC Explorer

MELSECNET/H control remote I/O network

QS Safety PLC

MS Configurator

Safety Relays

GX Developer GT Works3

36 MELSOFT

The iQ Works Software Suite contains four individual titles, MELSOFT Navigator, GX Works2, MT Works2, and GT Works3. Each of these titles can be purchased separately except for MELSOFT Navigator, which assists in complete network and system configuration and manages system labels across the different platforms.

RT Toolbox2 (LT) MELFA-Vision MELFA-Works

MELSECNET/H (PLC to PLC network)

STATION No. x10 1 2 3 4 0

x1

1

GCC1 09

5 6

2 3 8 7

4 5 6

L RUN/L ERR.

SLD DG DB DA

GT Works 3

MT Works2

WS Configurator

SoftGOT GT Works3

L Series PLC to PLC & Remote I/O

ST I/O

ST Configurator

A J65BTB1-16D

B RATE 0 1

PW L RUN

SD

1

4

RD L ERR. 4

0

2

3

5

6

7

8

9

A

2 3

STATION NO. X10 X1 0 1 9 0 1 2 8 2 3 7 3 6 5 4

B C D E F

6 5 4

1

3 DA

+24V

4 DB

7

5 DG

2

9

11

13

15

19

17

21

25

23

27

24G

6

8

10

12

14

16

18

20

22

24

26

SLD

(FG)

QS0J65BTB2-12DT Safety I/O

AJ65BTB1-16D CC-Link I/O

MELSOFT 37

Software

MELSOFT Mitsubishi Electric brand software (MELSOFT) provides customers with intuitive tools that reduce their total cost of ownership and speeds time-to-market. MELSOFT products are used throughout the automation asset’s lifecycle; development, commissioning, and maintenance. During the development stage, MELSOFT products are used to design systems which incorporate the entire portfolio of automation products. Powerful simulation tools are used to reduce programming and debug time before product deployment. Machine operators benefit from visualization products to further increase operation efficiencies during regular run-time and maintenance. Empowering developers to configure and commission their systems effectively and efficiently makes MELSOFT the preferred programming line by automation professionals around the world.

iQ Platform Integrated System Programming Suite - iQ Works The next generation in industrial software has arrived with the release of the iQ Works suite. The concept of this next generation is efficiency through integration. The iQ Works suite contains and maintains four different core software packages; MELSOFT Navigator, GX Works2, MT Developer2, and GT Works3. Between the four of them, the bundled packages enable developers to perform system configuration, sequence control programming, networking setup, motion control SFC program and mechanical editor implementation, HMI screen design, complete application simulation, batch program/ parameter installation, extensive debugging/monitoring/maintenance, and software file backup and organization.

• Advanced data sharing and gateway functions (FTP, email, client/server functions and MES capabilities) • Highly advanced maintenance, preventative maintenance and diagnostics

MELSOFT Navigator MELSOFT Navigator is the umbrella software that serves as the system configuration software and launching pad for the other three packages. Users are able to graphically assemble their networks, controllers, special function modules, and I/O for sequence control, along with their motion controller modules and GOT1000 HMIs. Brief details and descriptions are shown for each of the drag-and-drop style elements. Module configurations within each Q Series Programmable Automation Controller (PAC) backplane rack are checked for errors. Invalid configurations are rejected to prevent system malfunction. Power consumption is calculated for easy power supply selection. Multiple PAC, Motion Controller, and HMI projects are archived within the workspace folder structure for quick-access and possible version roll-back. System and Global variables, known as Labels, are managed between all projects. And each of the other three software executables are only a double-click away.

38 Software

Software

GX Works2 GX Works2 is the next generation configuration and programming software for FX and Q Series controllers. Following the goal of maximum efficiency, GX Works2 allows developers to mix and match between five different programming languages, each conforming to a different programming style. It is left up to the developer to select the language most comfortable and best suited for the job. This environment conforms to IEC1131-3 standards, also allowing parts of projects to be saved in Libraries for use within future applications. That means once a function, function block, program, or structure is written, tested, and proven, it can be integrated into new systems within minutes. Completely customizable environment layouts follow the installation and not the project, meaning tool selection and shortcuts are optimized following the user’s own intuition. Built-in network and special function module configuration tools keep project files organized and easy to access. Special function module parameters are setup using prompts and pull-down menus, not through arbitrary bit and byte assignments. A built-in virtual PLC on the computer enables complete system simulation before hardware even arrives on site. After the project is downloaded to the actual system, GX Works2 includes numerous monitor modes, trace functions, and online debugging capabilities to put the finishing touches on the application and speed it to commission status.

MT Works2 MT Developer2, part of MT Works2, is the next generation programming, configuration and maintenance software for Q Series Motion Controllers including the iQ Platform, MR-MQ100 and Q170MCPU Stand-Alone motion controllers. Many improvements have been made based on user feedback. MT Developer2 offers a new and intuitive programming, design, and maintenance environment which can be used across many industries and applications in all the phases of a Motion Controller configuration; system design, program development, debugging, startup, operation, and maintenance.

Some of the key improvements are the ability to import and export third party camming profiles, added label and structured data type programming, powerful monitoring and debugging options, a built-in digital oscilloscope for trace functions, increased password security for OEMs, and improved printing options. Expanded functions and improved operation optimizes work efficiency.

GT Works3 GT Works3 is the design and configuration software for the GOT1000 Series HMIs. This revolutionary and intuitive design environment provides a host of attributes and graphical elements needed to quickly and easily develop visualization projects.

GT Works3 offers many convenient and time saving functions every programmer can appreciate. Programmers from all backgrounds and skill levels can navigate and access detailed project, system and screen settings quickly. Data entry fields, dialog windows even placement aids have been optimize to reduce development time and provide the flexibility every programmer demands. The standard graphics library offers one of the most comprehensive collections of realistic and sophisticated elements on the market. After screen development is complete, one touch simulation enables developers to debug and verify their projects using real-time variables and conditions.

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Robots

DID YOU KNOW? Mitsubishi Electric has been designing and manufacturing leading edge robotics since 1980.

Mitsubishi Electric’s robotic products focus on high-accuracy, high-speed applications in the small to medium payload class as well as many specialized applications. In addition to being among the fastest and most accurate in their class, Mitsubishi robots boast a long list of convenient features and connectivity options.

RH Series SCARA Robots RH Series

The RH Series of SCARA robots are suited for high-speed, high accuracy applications requiring only four degrees of freedom. Payloads are 6, 12 or 20 kg with various reaches up to 1000mm.

RV Series Vertically Articulated Robots RV Series

RP Series

Mitsubishi Electric’s RV Series of 5 and 6 axis vertically articulated robots offer total flexibility for a wide range of general applications up to 12 kg.

RP Series Micro Assembly Robots The RP Series utilizes a unique 5 joint, closed mechanical link design which provides a low mass, highly rigid arm. The RP has unmatched repeatability of ± 5 microns.

Network Flexibility In addition to standard Ethernet, Mitsubishi Electric robots offer several connectivity options such as CC-Link, Ethernet I/P, DeviceNet, and PROFIBUS.

Pendant Options Two new pendant options are available for the SD and SQ robots, the R32TB and R56TB. Both address the need for ease of use and user comfort. The R32TB performs all major functions, while the R56TB is customizable, graphical, and provides the additional functionality of RT-TOOLBOX features without the need of a PC.

R32TB • Teach pendant for all SD and SQ Series robots • 8 line x 24 character display • Ergonomic design • Basic teaching, program edit, parameter edit, and movement • Right hand or left hand operation 3-position switch for safety and comfort • Built-in E-Stop switch • Available with 7 meter or 15 meter cable

40 Robots

R56TB • Enhanced teach pendant for SD and SQ Series robots • 6.5" VGA touch screen • Enhanced on-screen editing and navigation • Right hand or left hand operation 3-position switch for safety and comfort • Built-in E-Stop switch • Customizable screen capability • Built-in USB port • Available with 7 meter or 15 meter cable

Robots

Whether your application requires only a robot or the robot is part of a larger platform, Mitsubishi Electric offers two major control configurations. The SD robot can stand alone while communicating with most any peripherals or third party control scheme. The SQ robot’s dedicated CPU leverages the strength of the iQ Platform.

SD robots are feature rich with a long list of standard features including: • Payload capacities up to 20 Kg • General environment ratings to IP65, oil-mist, or clean room models • AC servo motors with absolute encoders and brakes • Internal accessory wiring and piping • Superior repeatability and cycle time • Conveyor tracking function • Simplified vision interface tools • Additional axis control • Sensorless collision detection • Individual axis torque monitoring • Load-based acceleration optimization • Singularity point control routines RV-SD or RH-SD • Compliance control Robot • Multi-tasking program environment • Position restoration tool • Maintenance forecast function

Controller (Stand alone)

Robot CPU Q172DRCPU

SQ robots share most of the same features of SD robots while adding the flexibility of iQ Platform integration such as: • Simplified integration with other machine requirements • Faster system commissioning • Shared I/O and special function modules • Less wiring

iQ Platform PAC

RV-SQ or RH-SQ Robot

Controller

Software Mitsubishi’s suite of software products provide powerful yet simple analysis and visualization tools. These tools are indispensable to engineers and plant personnel to effectively deploy Mitsubishi robots in manufacturing applications.

Training Mitsubishi University offers “hands-on” training classes (each student has their own laptop and robot cell) to enhance the students’ learning experience. Customers have a choice of attending classes in Mitsubishi’s Illinois office or arrange for on-site training classes.

Technical Support Mitsubishi has world class service and technical support. Service personnel will be dispatched to customer locations from the quickest or nearest point on the national service network. 24/7 telephone and online support are also available.

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CNC

DID YOU KNOW? Mitsubishi Electric currently has over 78,000 CNC systems in operation in North America. Mitsubishi Electric has been producing high-performance CNC systems since 1973, and is the largest supplier of customized CNC systems for machine tool builders worldwide.

C70 Rack Based Multi-Axis, Multi-System CNC for Line-Dedicated Machines • Rack-based CNC system ideal for manufacturing cells, transfer lines and rotary dial machines • Up to 16 axes and 7 separate part program paths per C70 module with a maximum of two C70 units per rack • Fully customizable HMI with a built-in CNC monitor • Multiple networking options: • Ethernet Information Network • MELSECNET, PROFIBUS control networks • CC-Link, DeviceNet, PROFIBUS field networks • Complete line of digital servo and spindle systems • Same platform of programming software that is used with factory automation products • Complete safety package for door interlocks, light curtains, E-Stop circuitry

M700V Series, High Productivity, High Accuracy, Easy Operability • High performance CNC with PC based HMI • Block processing time as fast as 0.4ms • 3D solid model graphics • NC Designer software allows for easy screen customization • Full 5-axis machining capability • Multiple language support, 13 languages built-in • Servo motors up to 5000 rpm • Complete line of optically networked servo and spindle drive and motor systems • Up to 16 million pulse servo motor encoders

42 CNC

M70V Series, Standard Control for Various Types of Machining Applications • Panel mounted CNC • Complete line of digital servo and spindle systems • Front CF Card/IF for system backups, large capacity programs can be edited (up to 10MB) • NC Designer software allows for easy screen customization • Shop floor programming can be performed easily with the use of Navi-Mill or Navi-Lathe • Guidance functions available for G-Code, Alarm and Operation • Multiple language support, 15 languages built-in

CNC

MDS-D/DH

MDS-DM

MDS-D-SVJ3

MDS-D/DH Series Amplifiers • 200V and 400V compatible • Range from .2kW to 15kW servos and 2.2kW to 75kW spindle • Line regeneration for saving energy • Compact design for saving space • Full current loop control • Nano command control • High-speed optical drive network

MDS-D-SVJ3 Series Amplifier

Servo Motors • Medium inertia motors for high accuracy machining • Low inertia motors for high acceleration machining • Available in 260K, 1M, and 16M pulse per rev absolute encoders • Motors range from .2kW to 15kW

Spindle Motors • Variety of different motor styles in lineup • IP44 rated • Size range from .2kW to 55kW

• Ultra-compact drive with built-in power supply • High-speed optical drive network • Range from .2kW to 3.5kW servos and .75kW to 11kW spindle

MDS-DM Series Amplifier • High performance multihybrid amplier • Supports 2 or 3 servo axes and a spindle in one unit • Line regeneration for energy savings • Range from .5kW to 3.0kW servos and 5.5kW to 15kW spindles

Servo Motors

Spindle Motors

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Support & Services

Toll Free Assistance • Our highly trained and skilled engineers ready to help Monday-Friday 7AM-7PM Central 1-800-950-7781

On-Line Support • If you prefer written communication, visit www.meau.com/contactus

24/7/365 Support with ESSPSM • Rest assured knowing that you are covered by our Extend Support & Service Programs

On-Site Application Support • We have the ability to review your application and improve your process

Standard Training • Proven classes that give your maintenance or engineering group what they need

Custom Training • We can train your personnel at your facility with your application in mind

Trainer Kits • Rugged, portable and designed to do the job

Documentation • Whether on our website (www.meau.com) or on our MELDOC-DVDSM, we provide over 3000 manuals and CAD files with our powerful search engine.

Global Account Management • Strong global presence for our customers with total project management support including world-class training, spec generation, application development, spare parts, start-up services, and OEM/SI coordination.

44 Support & Services

Support & Services

For more information on Mitsubishi Electric’s World Class automation products and solutions, please visit

www.MEAU.com

Support & Services 45

Mitsubishi Electric Automation, Inc. 500 Corporate Woods Parkway Vernon Hills, IL 60061 Phn: (847) 478-2100 Fax: (847) 478-2253

• Programmable Automation Controllers

Mitsubishi Electric Automation, Inc. 4299 14th Avenue Markham, Ontario L3R 0J2 Phn: (905) 475-8989 Fax: (905) 475-7935

• Motion Controllers

• Programmable Logic Controllers • Human Machine Interfaces

• Servo Systems • Variable Frequency Drives • Robots

Printed with soy inks.

L-VH-00063 • Effective September, 2011.

Specifications subject to change without notice.

• Computerized Numerical Controls

©2011, Mitsubishi Electric Automation, Inc.

• Low Voltage Switchgear

www.meau.com

847-478-2100