The Powerhouse of Automation: Unveiling the Unmatched Capabilities of Mitsubishi MELSEC iQ-F series PLCs

In the dynamic world of industrial automation, precision, efficiency, and reliability are paramount. Enter the Mitsubishi iQ-F series PLC, a powerful and versatile programmable logic controller system that has been making waves in the automation industry. As manufacturing processes become increasingly complex, the iQ-F series PLC offers a comprehensive solution designed to streamline operations, enhance control capabilities, and drive productivity to new heights.

Overview of the iQ-F Series PLC

Mitsubishi’s iQ-F series products are designed with state-of-the-art technology, making them ideal for a wide range of industrial automation applications. The series boasts an impressive lineup of modules that can be combined to create a custom solution for any automation challenge. The central piece of this series is the CPU module. It forms the core of the system and is responsible for executing control programs. The iQ-F series CPU modules have a fast processing speed and offer enhanced functionality compared to their predecessors. They are designed to handle even the most demanding automation tasks.

Additionally, the I/O module is critical in providing input and output signals to the CPU and other modules in the system. The iQ-F series I/O modules feature user-friendly wiring terminals, reducing installation time and cost. The analog control module, on the other hand, is responsible for handling analog signals like low/high voltage or current. The highly accurate and fast response of iQ-F’s analog control module helps users in precise control processes.

The high-speed counting module is ideal for high-precision speed measurement, making it an essential component for motion control applications. This module facilitates fast and accurate counting, ensuring precise rotational and linear motion control. The iQ-F series also provides modules that enable real-time communication with other devices or systems.

Regarding safety, the iQ-F series has a separate safety extension module that enables the system to comply with international safety standards. This module provides a simple, easy-to-use safety system with various safety functions with fewer wiring and components.

Moreover, Mitsubishi offers other options, such as bus conversion, power supplies, and battery lineups, allowing the iQ-F series to be used in a broader range of applications.

CPU Modules

The CPU modules are the backbone of the iQ-F series lineup and consist of four main models to fit into a vast range of applications and environments. Each model will come with a built-in SD card slot capable of up to 16GB of extra storage and a 10BASE-T/100BASE-TX Ethernet port for socket communication, remote maintenance, and SLMP communication. 

The FX5U flagship module is a versatile and powerful controller designed for various industrial automation applications. With its impressive specifications, the FX5U module offers enhanced control capabilities and reliable performance.

• Control Scale: 32-384 points, with a maximum of 512 points, including CC-Link integration.
• Memory: 128k steps for storing control logic and programs.
• Analog/Digital: 2 channels of 12-bit Analog-to-Digital (A/D) conversion and 1 channel of 12-bit Digital-to-Analog (D/A) conversion.
• RS-485 Port: Enables serial communication with external devices and systems.
• Built-in Positioning: Supports positioning for four axes with 200 kHz pulse output for precise motion control.
• Built-in High-Speed Counter: Up to 8 channels of 200 kHz high-speed pulse input for accurate event monitoring.

The FX5UC expansion module, designed for compatibility with the FX5 and FX3 expansion modules, offers a compact and user-friendly solution to streamline system downsizing. With various conversion modules available, it enables easy connectivity to the FX5 and FX3 modules. Here are the key parameters and features of the FX5UC module:

• Control Scale: Ranging from 32 to 384 points, with the CPU module available in 32/64/96 point configurations. The module supports a maximum of 512 points, including CC-Link integration.
• Program Memory: Offers a generous capacity of 128k steps, allowing for the storage and execution of complex control logic and programming tasks.
• RS-485 Port: Conforming to RS-485 and RS-422 standards, the module provides an additional serial communication interface for connecting to external devices and systems.
• Built-in Positioning: Featuring built-in positioning capabilities, the module supports precise control of up to four axes with a pulse output frequency of 200 kHz. This allows for accurate motion control in various applications.
• High-Speed Counter: The module offers a maximum of eight channels of high-speed pulse input, with a frequency of 200 kHz. The FX5UC-32M variant provides six channels at 200 kHz and two channels at 10 kHz for enhanced versatility in monitoring fast-paced events.

The FX5UJ module is cost-effective while offering a range of features and parameters that make it suitable for various industrial automation applications. Here’s an overview of its key specifications:

• Control Scale: The FX5UJ module supports a control scale ranging from 24 to 256 points, with the CPU module available in 24/40/60 point configurations. It allows for a maximum of 256 points, including CC-Link integration.
• Program Memory: With a capacity of 48k steps, the module provides sufficient space for storing control logic and program code.
• RS-485 Port: The module conforms to RS-485 and RS-422 standards.
• Built-in USB Port: The FX5UJ module includes a built-in USB port with a Mini-B connector with a maximum data transfer speed of 12 Mbps.
• Built-in Positioning: The module offers built-in positioning capabilities for up to three axes, providing precise control with a pulse output frequency of 200 kHz
• High-Speed Counter: The module supports a maximum of eight channels of high-speed pulse input with a frequency of 200 kHz. In the case of the FX5UC-32M variant, it provides four channels at 200 kHz and four channels at 10 kHz, expanding the range of high-speed pulse input options.

The FX5S module offers a compact and reliable solution for industrial automation applications focusing on IoT functions and ease of use. Here are the key parameters and features of the FX5S module:

• Control Scale: The FX5S module supports a control scale ranging from 30 to 60 points, with CPU module options available in 30/40/60 point configurations.
• Program Memory: The module offers a program memory capacity of 48k steps.
• Built-in USB Connector: The FX5S module features a built-in USB connector with a Mini-B interface with a maximum data transfer speed of 12 Mbps.
• Built-in Positioning: The module includes built-in positioning capabilities for up to four axes with a pulse output frequency of 100 kHz.
• High-Speed Counter: The module supports four channels of high-speed pulse input with a frequency of 100 kHz as well as four channels at 10 kHz for expanded high-speed pulse input options.

Safety Extension Modules

When it comes to safety, there are two modules to choose from in the iQ-F family, comprised of the main module (FX5-SF-MU4T5) and the safety input expansion module (FX5-SF-8DI4). Each module is SIL3 certified and has a performance level of PL e (DIN EN ISO 13849-1). Also included in the software are nine types of built-in programs that a physical rotary dial can access. The main module has four safety inputs and four safety output points, whereas the expansion module only has eight safety input modules.

An effortless installation of a safety control system entails connecting a safety main module (FX5-SF-MU4T5) to an FX5U/FX5UC/FX5UJ CPU module. This unified system enables both general-purpose control and safety control, eliminating the necessity for wiring associated with safety status monitoring (typically required with a safety controller) or wiring between relays in constructing a safety relay system. As such, redundant wiring is no longer needed, enhancing efficiency and ease of use.

High-Speed Counting Modules

Mitsubishi’s high-speed counting modules are designed to accurately and precisely measure fast-paced events in industrial automation applications. These modules offer high-speed pulse input capabilities, allowing for efficient monitoring and counting of rapid movements or processes. Their ability to handle high-frequency signals ensures reliable data acquisition and analysis. The high-speed counting modules enable engineers to capture and track events precisely, contributing to enhanced control, improved efficiency, and effective monitoring of critical processes in diverse industrial settings. While the CPUs can provide high-speed counting, both a high-speed counter module and a high-speed pulse input/output module are available separately.

The high-speed counter (FX3U-2HC) is a two-channel add-on module for the FX5U and the FX5UC CPUs. Its highest response frequency for both one phase one output and one phase two output is 200 kHz max, while its two-phase two input is a bit more complicated at one edge count of 200 kHz max, two edge count 100 kHz max, and four edge count 50 kHz max.

Both the FX5-16ET/ES-H and the FX5-16ET/ESS-H are available as input/output pulse modules. They both support a maximum of 2 channels at 200 kHz and are equipped with a high-speed counter function, pulse width measurement function, pulse catch function, and general input functions. These modules also come with eight 24V DC input and eight output points.

I/O Modules

I/O modules are truly the cornerstone of automation. These I/O modules include input, output, and powered I/O modules, each serving a specific purpose. The input modules facilitate data acquisition from sensors and devices, supporting a variety of digital and analog input types. Output modules enable precise control of actuators and devices, providing digital or analog output signals. Powered I/O modules combine input and output functionalities into a single module, offering a compact and integrated solution.

Powered I/O Modules: There are two versions of these modules, an AC power supply type and a DC power supply type, and three sub-models for both. They all are equipped with screw terminal blocks and 32 I/O points total. Sixteen are 24V DC (sink/source), while the other 16 output points consist of relays and transistors (both sink and source), depending on the model.

Input Modules: There are seven total input modules to choose from, ranging from 8 input points to 32 total. These modules accept a 24V DC input for their signal and can be attached to an FX5U, FXUC, and FX5UJ.

Output Modules: There are almost twice as many output modules as inputs at 13 total split across six main modules. The sub-modules are split to allow users to pick if they would like a sink, source, or relay output module. You could expect between 8 to 32 output points, depending on which module you pick.

Input/Output Modules: There are three main models and seven sub-models depending on what output you prefer, whether it is relay, sink, or source. The configuration is either eight inputs and eight outputs or 16 inputs and 16 outputs. Each is compatible with the FX5U, FX5UC, and FX5UJ.

Analog Modules

In addition to its digital I/O capabilities, the Mitsubishi iQ-F series PLC offers a range of analog modules that enable precise data acquisition and control of analog signals. These analog modules expand the capabilities of the iQ-F series PLC, allowing for the integration of analog sensors, actuators, and devices into automation systems.

Analog Input Modules: The analog input modules of the iQ-F series PLC provide the ability to acquire analog signals with accuracy and precision. These modules support a variety of analog input types, including voltage, current, and temperature. They offer high resolution and fast sampling rates, ensuring reliable measurement of analog variables. With multiple channels available, engineers can monitor and capture data from multiple sensors simultaneously. The analog input modules also provide features such as signal filtering and scaling, enabling efficient data processing and integration into control strategies. For this section, there are five to choose from: FX5U CPU module, FX5-4AD-ADP, FX5-4AD, FX5-8AD, and FX3U-4AD. These devices range from two to eight channels, depending on the model.

Analog Output Modules: The analog output modules of the iQ-F series PLC allow for precise control of analog devices such as motors, valves, and variable speed drives. These modules generate accurate analog output signals based on control instructions received from the PLC. With high-resolution digital-to-analog converters, they deliver smooth and precise control of analog variables. The analog output modules support various output types, including voltage and current, providing flexibility to interface with different analog devices in industrial processes. There are four to choose from, including the FX5U CPU, FX5-4DA-ADP, FX5-4DA, and the FX3U-4DA.

Temperature Input Modules: Specifically designed for temperature measurement applications, the iQ-F series PLC offers dedicated temperature input modules. These modules accept signals from various temperature sensors, including thermocouples, platinum, micro voltage, and resistance temperature detectors (RTDs). They provide high-precision temperature measurements with excellent stability and accuracy. The temperature input modules often include cold junction compensation and linearization functions to ensure reliable and precise temperature monitoring. There are five modules to choose from that could fit nicely into most systems: The FX5-4AD-PT-ADP, FX5-4AD-TC-ADP, FX5-8AD, FX5-4LC, and FX3U-4LC.

Motion/Positioning Control Modules

The motion/positioning control modules of the iQ-F series PLC by Mitsubishi offer advanced capabilities for precise control of motion and positioning in industrial automation applications. These modules enable efficient control of motors and other motion devices, supporting functions such as point-to-point positioning, speed control, and torque control.

Motion Modules: The motion control modules of the iQ-F series PLC provide advanced capabilities for controlling the movement of motors and other motion devices. These modules support various motion control functions, such as point-to-point positioning, speed control, and torque control. With high-speed pulse output channels, they generate precise and synchronized motion control signals, ensuring accurate and smooth movement of motors in applications such as robotics, conveyor systems, and automated machinery. These modules come with the following features: Linear interpolation, circular interpolation, continuous trajectory, s-curve acceleration/deceleration control, synchronous control, cam control, and torque control. Both the FX5-40SSC-G and the FX5-40SSC-S have four axes of control, while the FX5-80SSC-G and the FX5-80SSC-S have eight.

Positioning Modules: The positioning control modules enable precise control of position-based operations. These modules support multi-axis positioning, allowing engineers to control the movement and position of multiple axes simultaneously. With high-speed pulse output channels, they generate position control signals with exceptional accuracy, enabling precise alignment, indexing, and synchronization of motion in complex automation systems. There are three models: The FX5-20PG-P with two axes of control and a maximum frequency of 200kpps, the FX5-20PG-D with two axes of control and a maximum frequency of 5Mpps, and the FX3U-1PG with one axes of control and a maximum frequency of 200kpps.

High-speed pulse input/output module: This module supports high-frequency pulse input for accurate data acquisition and analysis, allowing the PLC to monitor rapid movements and events with precision. Additionally, it provides high-speed pulse output for precise control of external devices, ensuring accurate motion control and synchronization. Both the FX5-16ET/ES-H and the FX5-16ET/ESS-H have two axes of control with a maximum frequency of 200 kpps.

Network/Communication Module and Options

Finally, we have a wonderful selection of terminal blocks, power supplies, and the Network module. These addons are plentiful and will do a fantastic job when paired with your existing system or replace parts that have worn out, such as terminal blocks. There are also various-sized SD cards for extra storage in the CPU modules, batteries to retain the status of a device in case of a power failure, and bus conversion modules.

On the network/communication side, the FX5-CCLGN-MS is a communication module that provides CC-Link IE Field Network connectivity for the FX5U series PLCs. CC-Link IE (Control & Communication Link Industrial Ethernet) is an industrial open network technology that allows for fast and reliable communication between various devices in a control system.

The FX5-CCLGN-MS module acts as a bridge between the FX5U PLC and the CC-Link IE Field Network, allowing seamless integration and communication with other CC-Link compatible devices such as remote I/O modules, servo drives, and other automation equipment. It provides a high-speed communication link with a data transfer rate of up to 1 Gbps, ensuring efficient data exchange and synchronization between devices.

Overall, the FX5-CCLGN-MS module empowers users to leverage the benefits of CC-Link IE Field Network technology, enabling seamless communication and integration with other devices in the industrial automation system.

This entry was posted on September 22nd, 2023 and is filed under Automation, Electrical, Mitsubishi, Selection Guide, Technology. Both comments and pings are currently closed.