MELSEC Tutorial 02 – Module Configuration Diagram

Creating a module configuration diagram is a critical step in setting up a MELSEC PLC system. This diagram serves as a visual representation of the modules and their connections, helping to ensure proper integration and functionality. In this tutorial, we’ll guide you through the process of designing and finalizing a module configuration diagram for your Mitsubishi Electric MELSEC PLC system.

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What is a Module Configuration Diagram?

A module configuration diagram outlines the arrangement and connections of various modules in a PLC system. It includes:

• Power Supply Module
• CPU Module
• I/O Modules (input/output)
• Communication Modules (if applicable)

This diagram provides clarity on module placement, wiring paths, and overall system layout.

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Step 1: Identify System Requirements

Before creating the configuration diagram, identify your system’s functional requirements:

1. Determine the I/O Count: Calculate the number of inputs and outputs needed for your devices.
2. Select Required Modules: Choose modules based on functionality, such as digital I/O, analog I/O, or special-purpose modules (e.g., high-speed counters).
3. Consider Communication Needs: If networking is required, select appropriate communication modules.

Example System Configuration

• Power Supply: Provides energy to all modules.
• CPU Module: Executes control logic.
• I/O Modules: Interfaces with sensors, switches, and actuators.
• Network Module: Connects to external systems like HMIs or SCADA.

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Step 2: Utilize MELSOFT Navigator

MELSOFT Navigator is Mitsubishi Electric’s software for system design and configuration.

Setting Up a New Project

1. Open MELSOFT Navigator and create a new project.
2. Choose the appropriate MELSEC PLC series (e.g., iQ R, iQ F, or FX).
3. Set up the project parameters, including CPU type and I/O specifications.

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Step 3: Arrange Modules in the Configuration Diagram

Adding Modules

1. Navigate to the Module Library within MELSOFT Navigator.
2. Drag and drop the following modules into the diagram workspace in the proper order:
   • Power Supply Module
   • CPU Module
   • I/O Modules
   • Communication Modules (if needed)

Connecting Modules

• Align modules to reflect the physical order in the PLC rack or DIN rail.
• Ensure logical connections between the CPU and I/O modules.
• Use software features to check compatibility between selected modules.

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Step 4: Validate the Configuration

Once the modules are arranged:

1. Run a Validation Check: Use MELSOFT Navigator to check for errors in the configuration, such as missing modules or incompatible connections.
2. Review Module Settings: Confirm that parameters (e.g., input voltage levels or channel counts) are configured correctly.
3. Save the Configuration: Save the project file for future use and modifications.

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Step 5: Document the Diagram

Creating a comprehensive documentation package ensures easier troubleshooting and scalability.

• Export the diagram from MELSOFT Navigator.
• Annotate the diagram with module names, part numbers, and connection details.
• Save both digital and printed copies for reference.

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Benefits of a Well-Defined Module Configuration Diagram

• Improved Clarity: Provides a clear visual layout for installation and troubleshooting.
• Error Reduction: Helps identify configuration issues before physical setup.
• Simplified Maintenance: Acts as a reference for system adjustments or repairs.

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Conclusion