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Mitsubishi Electric Corporation, Fukuyama Works
Mitsubishi Programmable ControllerMELSEC-Q Series
Energy Measurement Module (QE81WH)
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Energy Measurement Needs in Production Equipment Systems
Meets the need for detailed energy saving
monitoring by measuring each production
equipment’s active energy.
•••• Energy monitoring of each production line process /production equipment.
•••• Detailed energy consumption rate management•••• For each control timing
•••• Short tact processes (for each tire, each semiconductor wafer, etc.)
•••• For lines having multiple product types (beverages, etc.)
•••• For uncountable products (sheet-shaped products, etc.)
Energy Efficiency Management
Meets the need for optimal operation of
equipments by measuring production
equipment’s active power or current.
•••• Reduces wasteful energy consumption during equipment startups (machine overshoots, etc.)
Suitable operation needs
Meets the need for prevention of sudden
failures by measuring active power or
current of production equipments.
•••• Lubricant is supplied when active power (or current)level rises
•••• Grinder (cutting machine) blade is changed when current increases.
Preventive Maintenance
Meets the need for management of
production items in abnormal state by
detecting voltage and current errors of
production equipments.
•••• Detection of heater wire breakage (current)•••• Quality assurance through voltage, current, and
frequency management, etc.
Product quality control
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(1) Can be mounted directly into the MELSEC-Q slot →→→→ Space-saving(2) No need for communication module, communication line, or communication ladder
program →→→→ Reduction of wiring work and cost(3) Specific energy consumption can be managed by linking electric energy with production
units →→→→ Easy measurements & easy specific energy consumption management
Product Concept
To load
GOTQ-Series
Programmable Controller
•••• Energy measurement
module (Measured items)
• Current• Voltage• Electricity• Electric energy, etc.
Machine's main breaker
Current sensor
電流入力
Voltage input
QE81WH1kRUNERR.ALM1ALM21l3k3lP1P2P3FGMEA.R13
Current input
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Space-saving
• Mountable into MELSEC-Q series Programmable Controller• Importation of current by compact sensor
Can be mounted without changing the panel size
Control panelQ02UCPUMODERUNERR.USERBAT.BOOTUSBRS-232QX40 QY40PPOWER QD60P8-GRUNERR. CH1CH1CH1CH1CH2CH2CH2CH2CH3CH3CH3CH3CH4CH4CH4CH4 CH5CH5CH5CH5CH6CH6CH6CH6CH7CH7CH7CH7CH8CH8CH8CH8
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Current sensor Q E81W H1kRU NER R.A LM 1A LM 21l3k3lP1P2P3FGM EA.R13
Control panelQ02UCPUMODERUNERR.USERBAT.BOOTUSBRS-232QX40 QY40PPOWER QD60P8-GRUNERR. CH1CH1CH1CH1CH2CH2CH2CH2CH3CH3CH3CH3CH4CH4CH4CH4 CH5CH5CH5CH5CH6CH6CH6CH6CH7CH7CH7CH7CH8CH8CH8CH8
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Energy measurement module
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Reduction of Wiring Work and Cost (1)• Communication module is not required to import data to Programmable
Controller (No need for an extensive measurement system)• Communication programs are not required, leading to the reduction of
programming workload.
Communication module and communication lines are not required
(cost reduction)
Measuring instrument(with communication function)
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L RU NS M STR DL ERR .×1M O DED G 1357246CC-Link, etc. Energy
measurement module
Communication module
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Reduction of Wiring Work and Cost (2)LED lamps indicate active energy status
The module is working properly."1" LED and "3" LED are both
OFF
OFFON
(1) Side 3 current sensor is installed backwards, or the positions of Side 1 and
Side 3 current sensors may be reversed.
(2) P2 and P3, or the P1 and P3 connections may be reversed
Only the “3" LED is ON
OFFor ON
ON
(1) Side 1 current sensor is installed backwards, or the positions of Side 1 and
Side 3 current sensors may be reversed.
(2) P1 and P2, or P1 and P3 connections may be reversed.
Only the "1" LED is ON
OFFor ON
ON
(1) Side 1 and Side 3 current sensors may be installed backwards.
(2) The voltage lines (P1, P2, P3) may be connected incorrectly.
"1" LED and "3" LED are both
ONONON
(1) The type of current censor may be incorrect. Use of sensor with a rating
different from the primary current setting may cause improper measurement.
(2) Wiring is not connected, or is connected incorrectly.
(3) The voltage lines (P1, P2, P3) may be connected incorrectly.
"1" LED and "3" LED are both
OFFOFFOFF
"1“ "3" LED"R" LED"MEA."LEDStatus
Check items
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Causes of incorrect wiring can easily be identified
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Easy Measurements & Easy Specific EnergyConsumption Management
• Can be measured by mounting directly into the MELSEC-Q slot (* sensor and voltage wiring required).• Specific energy consumption can be managed by linking electric energy level with production
counts (specific energy consumption management for each production item and each process).
Energy-saving + improved productivity
* "Specific energy consumption" is [amount of energy used ÷ production units], and it is an index representing one measure of energy productivity. Improving this specific energy consumption results in improved productivity.
Eliminating causes of poor
specific energy consumption resultsimproved productivity
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Energy Measurement Module Specifications (1)
Current input
terminal block(1-phase, 3-phase)
Voltage input terminal block
(1-phase, 2-phase, 3-phase, FG)
QE81WH1kRUNERR.ALM1ALM21l3k3lP1P2P3FG
MEA.R13 LED
(1) Appearance & structure
(2) Functions
The intelligent function module switch settings can be specified so that prescribed values are saved (in pseudo manner) in the buffer memory even when there are no voltage and current (sensor) inputs. By using this module, the test function can be used whencreating ladders, etc.
Test (debug)5
Up to 2 measurement items can be set (current (demand value), voltage, active power (demand value), and power factor), and theupper / lower limits of these items can be monitored. When either upper / lower limit violation occurs, a prescribed input signal switches ON.
Upper / lower limit alarm monitoring
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Maximum and minimum values for current demand, voltage, active power demand, and power factor can be saved with their occurrence date and time.
Max. & Min. value save
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Measures active energy only when specified output signal is ON, and stores the result in the serial buffer memory. "Period active energy 1" and "period active energy 2" measurements can be performed independently.
Period active energy measurement
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Following items are measured at 250ms intervals, and stores the result in the serial buffer memory: current (effective value, demand value), voltage, power (effective value, demand value), power factor, frequency, active power (consumption side, regenerative side), reactive power (consumption side lag).
Measurement1
DescriptionFunctionsNo.
(3) Standards
• CE Marking: Self-declaration• UL: Acquisition planned in 2011
Mitsubishi General
Purpose Programmable
ControllerMELSEC-Q series
Energy
Measurement Module
(Model: QE81WH)
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Energy Measurement Module Specifications (2)
Measurement of receiving active energy (consumption), and generating active energy(regenerative) is also possible.
Active energy (consumption, regenerative), reactive energy, current, current demand (*1), voltage, active power, active power demand (*1), frequency, power factor
Measured items
16 occupied input / output points (I/O assignment: intelligent 16 points)Number of occupied input / output points
Backed up by power failure compensation non-volatile memory.
(Saved items: Setting values, max. / min. values and their occurrence times, active energy (regenerative, consumption), reactive energy, period active energy)
Power failure compensation
Buffer memory is updated every 250msData update rate
Mounted on Q-Series Programmable Controller base unit.Mounting
27.4(W)××××98.0(H)××××90.0(D)mm Excluding protruding areasOuter dimensions
Incorrect wiring connection indicator function included.
None (output to Programmable Controller Q-series GOT, etc.)(Displays only RUN, ERR, ALM, MEA, R, 1, 3 on main LED)
Display
Actual measurement accuracy includes the current sensor accuracy value.
(1) Current, voltage, power, frequency: ±±±±1.0% (for rated input)(2) Power factor: ±±±±3.0%(3) Active energy, reactive energy: ±±±±2.0%
(within 5 to 100% of rated range, power factor = 1)
Measured factors & unit accuracy
Applicable primary voltages when using /110V VT (440, ..... , 6600V)
110V, 220V (single-phase 2 wires, 3-phase 3 wires), 110V, 220V (single-phase 3 wires) (440V or higher requires an external instrument transformer.)
Rated voltage
Applicable primary currents when using the 5A split-type current sensor (5,10,15, ....... , 6000A)
5A, 50A, 100A, 250A, 400A, 600A(To accommodate 600A or higher, the optional 5A split-type current sensor can be used together with a current transformer.)
Rated current
Single-phase 2 wires, single-phase 3 wires, 3-phase 3 wiresPhase wiring
RemarksSpecificationItem
*1: "Demand" is the average movement within the specified time period.
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Sensors and Cables
1 piece
EMU2-CB-T1M (1m)Split-type current sensor extension cable (standard type)
EMU2-CB-T5M (5m)
EMU2-CB-T10M (10m)
EMU2-CB-T5MS (5m)
EMU2-CB-T10MS (10m)
1 piece
EMU2-CB-T1MS (1m)Split-type current sensor extension cable (separate type)
1 pieceEMU2-CB-Q5ASplit-type 5A current sensor cable
1 set (Two 5A current sensors, with one 0.5m cable)
EMU2-CT5Split-type 5A current sensor
EMU-CT600
EMU-CT400
EMU-CT250
EMU-CT100
1 piece
EMU-CT50
Split-type current sensor
Sales UnitOuter AppearanceModelItem Name
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【Visualization of Production Site】
⇒Display of measurement data with GOT
installed in production equipment
<Procedure>
①Download a free sample screen from
MITSUBISHI ELECTRIC H@iSEIweb:
www.mitsubishielectric.co.jp/haisei/lvs/
Visualization by Using GOT
The default data saving period is 2 pages that
can be controlled with .
The data saving period can be easily be changed
by changing a program.
<Data Saving Period><Recommended GOT Model>
GOT1000 Series
Resolution:VGA
(Best suited for sample display)
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<Sample Display ①>
During which hour the electricity
consumption is high can be seen
through a graph
During which hour the average
electricity consumption is high can
be seen through a graph
Display range can be changed
GOT Sample Display (1)
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Specific consumption display (Electric power)
<Sample Display②>
Specific energy consumption graph
can easily be made, and losses
(spots that need to be improved) can
be checked.
Electricity fee specific consumption can
be visualized easily. It can lead to the
rise of energy saving consciousness in
production sites.
Aggravation of Specific Energy
Consumption = Improvement Spots
GOT Sample Display (2)
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【Visualization with Upper PC】
⇒ Display of data collected through supervisor PC’s high-speed data logger unit
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Supervisor PC
High-Speed Data Logger Unit
QD81DL96
<Procedure>
①Set layout, graph, calculating
formula on the PC
②Send the layout file set above to
the high-speed data logger unit
by using PC’s setting tool
Sample Excel file can be downloaded free from
MITSUBISHI ELECTRIC H@iSEIweb:www.mitsubishielectric.co.jp/haisei/lvs/
Visualization with PC (1)
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<Procedure Image>
Specific energy
consumption
management is easy
by linking production
data accumulated with
High-speed Data
Logger Unit and
energy information
from QE81WH.
Visualization with PC (2)
High-speed data logger module
Layout File
(Excel file type)
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Installation Example (1)
Energy Monitoring for Each Production
Line Process / Production Equipment
GOT
40%20%工程別使用電力量[kWh] 100%80%60%工程2 工程1 工程3 その他(非稼動)
GOT
GOT
GOT
LAN
High-speed data logger
module
Minute-by-minute data
management
Energy measurement
module
QE81WH1kRUNERR.ALM1ALM21l3k3lP1P2P3FG MEA.R13 Data logging by high-speed
data logger module
Process-specific power
energy consumption
(kWh)
Process 2 Process
1
Process 2
Other (idle
processes)
100%
80%
60%
40%
20%
GOTGOTGOTGOT
Meets the need for detailed energy saving monitoring by measuring each production equipment’s active energy.
•••• Energy monitoring of each production lineprocess / production equipment.
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Specific Energy Consumption Management for
Each Control Timing
Installation Example (2)
At the control point, the period active
energy measuring flag = ON.
At the control point, the period active energy
measuring flag = OFF.
Total active energyconsumption for this
process
Line controlling
Programmable
Controller
Energy measurement
module
QE81WH1kRUNERR.ALM1ALM21l3k3lP1P2P3FG MEA.R13 Measurement synchronized with the control timing is possible.
The Energy measurement module can measure ““““active energy of the whole production line", as well as a ““““active energy (period active energy) for partial process““““ simultaneously.
Process 1
Power energy consumption
(kWh)
Full
process
Process
1
Meets the need for detailed energy saving monitoring by measuring each production equipment’s active energy.
•••• Energy management linked with control timing•••• Detailed specific energy consumption management
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Preventive Maintenance for Equipments (Error Monitoring)
Upper / lower limit alarm monitoring(active power or current)
(Equipment’s error monitoring)
Equipment maintenance / repair
Shortening of equipment downtime leads to reduction of production loss
Installation Example (3)
Meets the need for prevention of sudden
failures by measuring active power or
current of production equipments.
•••• Lubricant is supplied when active power (or current) level rises
•••• Grinder (cutting machine) blade is changed when current increases
Alarm
Current value
Time
Alarm
monitor value
Alarm
Energy
measurement
module
QE81WH1kRUNERR.ALM1ALM21l3k3lP1P2P3FG MEA.R13Alarm
GOT
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Optimal Equipment Operation
Current monitoring during operation
Control method (sequence) is changed
Optimal equipment operation
+ energy-saving
Installation Example (4)
Meets the need for optimal operation of
equipments by measuring production
equipment’s active power or current.
•••• Reduces wasteful energy consumption during equipment startups (machine overshoots, etc.)
Current value
Time
After adjustment
Current value
Time
Before adjustment
Energy
measurement
module
QE81WH1kRUNERR.ALM1ALM21l3k3lP1P2P3FG MEA.R13Alarm
GOT
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Product Quality Control
A product is removed from the
production line when equipment
power error occurs
Prevents faulty products
from being shipped.
Installation Example (5)
Meets the need for management of
production items in abnormal state by
detecting voltage and current errors of
production equipments.
•••• Detection of heater wire breakage (current)•••• Quality assurance through voltage, current, and
frequency management, etc.
Upper / lower limit alarm monitoring(voltage, current, or frequency)(Power error monitoring during
equipment operation)Voltage
value
Time
Alarm monitor
value
Alarm
occurs
Energy
measurement
module
QE81WH1kRUNERR.ALM1ALM21l3k3lP1P2P3FG MEA.R13Alarm
GOT
Alarm
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QE81WH
Frequency
Current
Voltage
Power
Electricity
Power Ratio
Current value
is saved
every 250ms
Image of QE81WH’s buffer memory
【Energy Data of QE81WH】
⇒Current value is overwrite saved to QE81WH’s buffer memory every
250ms
Flow of Measurement Data Process①
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Q 02U CPUM ODERUNERR.USERBAT.BOOTUSBRS-232Q X40 Q Y40PPOWER Q D 60P8-GRUNERR. CH1CH1CH1CH1CH2CH2CH2CH2CH3CH3CH3CH3CH4CH4CH4CH4 CH5CH5CH5CH5CH6CH6CH6CH6CH7CH7CH7CH7CH8CH8CH8CH8 Q E81W H1kRUNERR.ALM 1ALM 21l3k3lP1P2P3FG M EA.R13
Frequency
Current
Voltage
Power
Electricity
Power Ratio
Image of QE81WH’s buffer memory
【Reading of Energy Data】
“Data reading program” is executed to QE81WH’s buffer memory
from CPU⇒
“Data Reading”
CPU Unit
Flow of Measurement Data Process②
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【Save Location of Energy Data Collected by QE81WH】
①
CPU’s device
memory (built-in)
②
CPU’s external CF card
③
GOT built-in memory
④
GOT external CF card
CFcard
⑤
High-speed Data
Logger Unit
③GOT memory (built-in)
⑤High-speed Data Logger Unit
④GOT memory (external)
①CPU’s device memory (built-in)
②CPU’s external memory
(compact flash (CF) card)
CFcard
※Measurement data cannot
be saved into QE81WH
module
Flow of Measurement Data Process③
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