QE81WH Energy

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Mitsubishi Electric Corporation, Fukuyama Works

Mitsubishi Programmable ControllerMELSEC-Q Series

Energy Measurement Module (QE81WH)

2

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

3

(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

4

Space-saving

• Mountable into MELSEC-Q series Programmable Controller• Importation of current by compact sensor

Can be mounted without changing the panel size

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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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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

2

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


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


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


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


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.


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


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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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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QE81WH Energy