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Mitsubishi Electric MELSEC iQ-R Series Introduction Manual

System recorder
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MELSEC iQ-R System Recorder Introduction Guide
(Recorder Module)
This guide describes the procedure for introducing a system recorder, which is one of our maintenance
solutions. The system recorder records the operation of the program data and error/event occurrences
during the system operation using the recorder module. By replaying the record in GX Works3, the past
system operation can be checked. To determine and analyze the trouble cause, reproduce the status of the
site where the trouble has occurred by using the GOT offline monitor or use the video recorded by a
camera together.
Record
Recorder module
...Saves sampling data in an SD memory card.
Camera recording package
...Saves the video data in the general-purpose
personal computer (Windows10).
Reproduction
Offline monitor function
GX LogViewer
GX Works3
Analysis
GX Works3 data flow analysis
GOT offline monitor
GX VideoViewer

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  • Page 1 MELSEC iQ-R System Recorder Introduction Guide (Recorder Module) This guide describes the procedure for introducing a system recorder, which is one of our maintenance solutions. The system recorder records the operation of the program data and error/event occurrences during the system operation using the recorder module. By replaying the record in GX Works3, the past system operation can be checked.

  • Page 2: Table Of Contents

    CONTENTS CHAPTER 1 OVERVIEW Introduction Flowchart ..............4 CHAPTER 2 PREPARATION Wiring .

  • Page 3: Chapter 1 Overview

    This document describes the procedures for setting the MELSEC iQ-R series recorder module RD81RC96 and network camera and functions of GX Works3 for implementing these three steps.
  • Page 4 System configuration In this document, the following system configuration is used as an example. (1) (2) Device/software Model IP address CPU module R16CPU 192.168.3.39 (default)  Recorder module RD81RC96 (For the recorder module, an SD memory card must be inserted.) Personal computer for setting GX Works3 ...

  • Page 5: Introduction Flowchart

    Introduction Flowchart Configure the settings and check the operation with the following procedures. For details, refer to Chapter 2 and subsequent chapters in this document. Do preparation such as wiring devices and inserting an SD memory card. Preparation  Chapter 2 Configure the recording settings to use the recording function.

  • Page 6: Chapter 2 Preparation

    PREPARATION Wiring The following shows the wiring described in this document. Connect the personal computer, CPU module, recorder module, network camera, general-purpose personal computer (Windows10), and GOT to the PoE switching hub using Ethernet cable. Programmable controller Personal computer for setting switching hub General-purpose personal computer (Windows10)

  • Page 7: Ip Settings Of Personal Computers

    IP Settings of Personal Computers Set the IP addresses of the personal computer for setting and general-purpose personal computer (Windows10). Operating procedure Set the IP address of the personal computer in "Internet Protocol Version 4 (TCP/IPv4)". Personal computer for Setting: 192.168.3.100 2 PREPARATION 2.3 IP Settings of Personal Computers...
  • Page 8 General-purpose personal computer (Windows10): 192.168.3.30 • Set the IP address so that it is in the same segment as the ones of the devices to be connected. • For setting IP addresses of the other devices, refer to the following. Programmable controller: Page 38 Programmable Controller Setting Network camera: Page 25 Network Camera Setting GOT: GT Designer3 (GOT2000) Screen Design Manual...

  • Page 9: Chapter 3 Recording Function

    RECORDING FUNCTION The recording function stores the devices, labels, and event histories of the CPU module in the recorder module, outputs the data within the saving period in a recording file when a file saving trigger is established, and saves it in the SD memory card. CPU module Recorder module SD memory card...

  • Page 10: Creating A New Project

    Creating a New Project Create projects for the CPU module and GOT. CPU module Set the following in GX Works3. Operating procedure Create a new project. Set the series to RCPU. Set the type according to the system configuration. Set the module configuration diagram. [Navigation] ...
  • Page 11 Confirm the parameters. Right-click the module configuration diagram  [Parameter]  [Fix] Click [Yes]. The recorder module is added. Click here. When the recorder module is added, the CPU parameters are automatically set. They are related to the following settings. Page 15 When configuring multiple recording settings,Page 79 Event History Function (Saving Device/ Label Operations) These two items are...
  • Page 12 Set the following in GT Designer3. Operating procedure Start GT Designer3. In New Project Wizard, configure the following settings to create a project. 3 RECORDING FUNCTION 3.1 Creating a New Project...

  • Page 13: Recording Setting

    Recording Setting Use GX Works3 to configure the recording setting of the recorder module. For details on the recording setting screen, refer to the following. MELSEC iQ-R System Recorder User's Manual (Application) Operating procedure Add a new recording setting. [Navigation] window  [Parameter]  [Recording Setting]  Right-click  [New] Click here to configure the recording setting.
  • Page 14 Select a recording method in the saving period setting. Recording Method: File Saving Trigger Only, Saving Period Before Trigger: 30 seconds, Saving Period After Trigger: 5 seconds Displays the approximate value of the processing time for sampling the devices/labels. Configure the device/label sampling setting. Specify Device/Label in batch: Selected (default) When Specify Device/Label in batch is selected, the devices and labels in the created program are automatically set as the sampling targets.
  • Page 15 Set the device to be used as the file saving trigger in the file saving trigger setting. Device: M0 (turning ON) 3 RECORDING FUNCTION 3.2 Recording Setting...

  • Page 16: When Configuring Multiple Recording Settings

    When configuring multiple recording settings Up to four recording settings can be configured. The buffer area setting for data sampling of the CPU parameter in setting 2 to 4 and recording buffer setting of the module parameter in the recorder module are set to 0 by default. Therefore, set the capacity for each setting.
  • Page 17 Configure the buffer area setting for data sampling in the CPU parameter. [Navigation] window  [Parameter]  CPU module to be used  [CPU Parameter] For the capacity to be specified in the buffer area setting for data sampling in the CPU parameter, the required size can be checked in the recording setting screen.

  • Page 18: Creating A Program

    Creating a Program The following program is used as a recording example. Set file saving trigger Create a GOT screen supporting the above program, and use it. Touch switch Lamp 3 RECORDING FUNCTION 3.3 Creating a Program...

  • Page 19: Writing

    Writing Write the parameters, program, and recording setting to the CPU module, and write the project data to the GOT. Then, reset the CPU module and GOT, or turn off and on the power of them. CPU module Operating procedure Start GX Works3 and connect to the personal computer.
  • Page 20 Select [Parameter + Program], and then click the [Execute] button. Click here. Click here to write the data. Operating procedure Start GT Designer3, configure the connection setting with the personal computer, and then click the [OK] button. [Communication]  [Write to GOT] from the menu Configure the settings as shown on the right.
  • Page 21 When the data cannot be written via Ethernet, connect the GOT and personal computer with a USB cable to write it via USB. Set the data to be written and writing destination, and then click the [GOT Write] button. Configure the settings as shown on the right.

  • Page 22: Recording

    Recording Operate the program described in "Page 17 Creating a Program" to perform recording, and read the record data from the recorder module. Operating procedure Switch the CPU module to the RUN state. Check that the RUN LED and OPR LED of the recorder module turn on. The recording function automatically starts when the CPU module is switched to the RUN state.
  • Page 23 M0 (file saving trigger) turns on. Error cause 2 (M50) turns on. Check that M0 (File saving trigger) is on. When the file saving trigger is established, the recording file is saved in the SD memory card of the recorder module. With the recording monitor, the operation of the recording function can be stopped and restarted, and the status can be checked.
  • Page 24 Read the recording file from the recorder module. [Recording]  [Read Recording File] Click here to open the read screen. When a window for checking the communication status appears, click the [OK] button. Click here. Select the recording file to be read, and click the [Read to Personal Computer] button to save it in the personal computer. Select.

  • Page 25: Chapter 4 Camera Recording Function

    CAMERA RECORDING FUNCTION The camera recording function records the captured footage of the network camera connected directly to the built-in Ethernet port of the CPU Module. The camera video is recorded when a trigger for executing the video recording event of the network camera is turned on in the CPU module, and the video recording file is saved in the general-purpose personal computer (Windows10).

  • Page 26: Network Camera Setting

    Network Camera Setting Use a web browser to configure the network camera setting. When the network camera is started up for the first time, network settings such as the IP address setting are required. At the second and subsequent start-up, the camera can be accessed by entering the password.
  • Page 27 When the web server is accessed, the administrator password setting window appears. Set a password and the language, and click the [Create login] button. • Set the password within 4 to 64 characters. • Do not use "$" in the password. Log in to the network camera.
  • Page 28 Select the power line frequency. Set IPv4 to "Manual IP and manual DNS", and set network parameters. IP address: 192.168.3.42 Turn off "Automatic date and time" and set the time manually. • Set the IP address and subnet mask in the same segment as the IP addresses of the CPU and general- purpose personal computer (Windows10).
  • Page 29 Set the IP address of the personal computer for setting again in the same segment as the network camera set in step 6. Enter the IP address of the network camera in the web browser, and access the web server again. After the setting is completed, the live view window appears.

  • Page 30: Date And Time Settings

    Date and time settings Set the date and time of the network camera. These settings are not required if they have already been set in the initial start-up setting. Operating procedure Log in to the network camera. Display the date and time setting window. [Settings] ...

  • Page 31: Video Recording Event Settings

    Video recording event settings Configure the video recording event settings. These settings use a virtual input as a trigger to save generated video files in the general-purpose personal computer (Windows10). Profile settings Operating procedure Log in to the network camera. Display the stream profile window.
  • Page 32 Enter a profile name in "Name", and set items such as resolution. Set each item of the profile to any of the following. Compression format Resolution Frame rate • H.264 • 19201080(16:9) 120, 100, 60, 50, 30, 25, 15, 10 •...
  • Page 33 Rule settings Operating procedure Display the event window. [Settings]  [System]  [Events] Click the [+] button. Set a rule name in "Name". 4 CAMERA RECORDING FUNCTION 4.1 Network Camera Setting...
  • Page 34 Set "Condition" to "Virtual input". For the virtual input port No., select a number within 1 to 32. Set the video recording period of the camera video. The video recording period can be selected from two settings. Setting Description (1) Recording the camera video before and after the video recording trigger Configure the following three settings.
  • Page 35 The following shows the images of the video recording period by each setting. (1) Recording the video before and after (2) Recording the video while the video the video recording trigger recording trigger is on (a) Video recording trigger ON (b) Video recording trigger OFF (c) Video data to be recorded (d) Video recording time before trigger...
  • Page 36 Video file save destination settings Operating procedure Set the save destination of video files. [Settings]  [System]  [Storage] Click the [Set up] button under "Network storage". Set the IP address of the storage destination of the video data (general-purpose personal computer (Windows10)) in "Host", and set the name of the folder to "Share", where the video data will be saved (within the general-purpose personal computer (Windows10)).
  • Page 37 When login to the general-purpose personal computer (Windows10) is required, select "The share requires login" and enter the login ID and password of the general-purpose personal computer (Windows10) in "Username" and "Password" respectively. Click the [Connect] button. 4 CAMERA RECORDING FUNCTION 4.1 Network Camera Setting...
  • Page 38 When the connection is succeeded, the status of the general-purpose personal computer (Windows10) is displayed. When the connection fails, the following window appears. Return to step 4 to correct the settings. Set the saving period of the video files in "Keep recordings up to". When the general-purpose personal computer (Windows10) runs out of space, the old recording files will be deleted regardless of the specified saving period.

  • Page 39: Programmable Controller Setting

    Programmable Controller Setting Parameter settings of the CPU module Start GX Works3, set the IP address and subnet mask of the CPU module, and configure the event history, external device configuration, and clock settings. Own node settings Operating procedure Display the own node setting window. [Navigation] window ...
  • Page 40 Event history setting Operating procedure To save device/label operations in the event history, set the following item to "Save". [Navigation] window  [Parameter]  CPU module to be used  [CPU Parameter]  [RAS Setting]  [Event History Setting] After the setting, click here.
  • Page 41 Click the [Close with Reflecting the Setting] button. Match the IP address and port No. of the sensor/device with the setting of the network camera set in the following. Page 25 Network Camera Setting Click the [Apply] button of the module parameter. 4 CAMERA RECORDING FUNCTION 4.2 Programmable Controller Setting...
  • Page 42 This setting is not required if the time synchronization setting by the NTP server is configured on the network camera side. For details on the time setting function (SNTP client) of the MELSEC iQ-R series CPU modules, refer to the following.

  • Page 43: Creating A Program

    Creating a program To record videos with the camera, creating the following two programs are required: one for setting the clock data of the CPU module in the network camera and another for executing the video recording event set in the network camera. Using the FBs of the camera recording package makes creating the sequence programs easy.
  • Page 44 Select the library (mslm file) of the camera recording package, and then click the [Open] button. The FBs are registered to the library. 4 CAMERA RECORDING FUNCTION 4.2 Programmable Controller Setting...
  • Page 45 Program example ■Global label list Define the global labels as follows. *1 The initial value is the connection No. of the active connection module set in the external device configuration. Page 39 External device configuration *2 The initial values are the user name and password set when the network camera is started up for the first time. Page 25 Initial start-up setting Although labels are used in this sample program, devices can be created as well.
  • Page 46 ■M+CameraRecord_AXIS_SetTime_R The clock data of the CPU module is synchronized with the network camera five seconds after the program is run. Description For the virtual input port No., specify the port No. set in the event window of the network camera. Page 32 Rule settings Set the device to execute the FB.

  • Page 47: Writing

    ■M+CameraRecord_AXIS_EventTrigger_R Turning on the file saving trigger device executes the video recording event set in the network camera. Description Set the device to be the trigger for executing the video recording event. In the sample program, the device used for the file saving trigger (M0) is set. Set these items in the same manner as the example of M+CameraRecord_AXIS_SetTime_R.

  • Page 48: Gx Videoviewer

    GX VideoViewer The video recorded with the network camera can be replayed in GX VideoViewer by Mitsubishi Electric. This section describes how to use GX VideoViewer. Add log markers to positions assumed to be the causes of the device error occurrence, and read the log marker information file (*.vms) in GX Works3.
  • Page 49 Replay the video with the button. Make a log marker at any position in the video with the button. A bar in a color other than red indicates the position where the log mark is made. The frame-by-frame playback can be performed in the positions where the log markers have been made with buttons.
  • Page 50 When using two or more cameras When using multiple cameras, use the log marker information read function to check the video of each camera at the same time. The following describes an example. By reading the log marker added in the video of Camera A to the video of Camera B, a log marker is added to the position at the same time to check.
  • Page 51 Select the replay window for the video of Camera B, click the [Read Log Marker information] button. The selected window is surrounded by a light blue frame. Open the log marker information file (*.vms) described in step 1. 4 CAMERA RECORDING FUNCTION 4.3 GX VideoViewer...

  • Page 52: Chapter 5 Offline Monitor Function

    OFFLINE MONITOR FUNCTION This chapter describes the offline monitor function for monitoring the data recorded by the system recorder offline. This function reproduces the status at the during the error on the engineering tool by using the device/label data and event histories saved in the programmable controller (recorder module) to replay the trouble on the offline monitor.
  • Page 53 The offline monitoring starts. Event history (Offline monitor) Seek bar ■Seek bar The seek bar is a function for specifying the index (serial number to be recorded in the recording file per scan) of the data to be monitored. The seek bar can apply the specified index or the monitor value of the index to the linked monitor screen, "Event History (Offline Monitor)"...
  • Page 54 Displaying waveform data Display the devices/labels selected in the monitor screen of the offline monitor function in a graph in GX LogViewer. Operating procedure Select a device in the program editor or watch window. Select the device. Select the waveform display. Shortcut menu displayed by right-clicking ...
  • Page 55 Precautions Up to 32 devices/labels can be registered to GX LogViewer. The seek bar in GX Works3 and the red cursor in GX LogViewer are linked. Moving the slider on the seek bar in GX Works3 moves the red cursor in GX LogViewer, and moving the red cursor in GX LogViewer moves the slider on the seek bar in GX Works3 in synchronization.
  • Page 56 The GOT offline monitor is displayed. 5 OFFLINE MONITOR FUNCTION...
  • Page 57 Replay Function is synchronized with the seek bar (editor, event hirstory and GX LogViewer) In synchronization with the movement of the slider on the seek bar, the editor being monitored offline, Event History (Offline Monitor) window, and red cursor in GX LogViewer move. The movement of the slider on the seek bar is applied to the editor being monitored offline.
  • Page 58 Replay Function is synchronized with the seek bar (GOT offline monitor) The monitor screen of the GOT synchronized with the movement of the slider on the seek bar can be displayed and checked. Offline monitor (GX Works3) GOT offline monitor (GT Designer3) At normal operation At device error 5 OFFLINE MONITOR FUNCTION...
  • Page 59 Replay Function is synchronized with the seek bar (resource file biewer of the GOT offline monitor) The time of the seek bar and events of the GOT (operation history and alarm history) can be synchronized mutually to replay the status of the site. Offline monitor (GX Works3) Resource file viewer (GOT offline monitor)

  • Page 60: Chapter 6 Data Flow Analysis Function

    DATA FLOW ANALYSIS FUNCTION The data flow analysis function automatically creates a data flowchart from the GX Works3 program to visually display the execution conditions of a specific Device/Label. The following describes the procedure for starting the operation of the data flow analysis function. Operating procedure Start GX Works3, and open the program.
  • Page 61 The data flow is displayed. Click the [Start Monitoring] button. The monitor value of the device/label is displayed. 6 DATA FLOW ANALYSIS FUNCTION...

  • Page 62: Overview Of Data Flow Analysis

    Overview of Data Flow Analysis In the data flow analysis, the device/label to be analyzed is displayed in the center as the basing point. The block which affects the device/label to be analyzed is displayed on the left, and the one to be affected is displayed on the right. Affecting block Device to be Affected block...

  • Page 63: Chapter 7 Operation Example

    OPERATION EXAMPLE Chapter 3 through Chapter 6 describe the settings and how to start the functions of the record, reproduction, and analysis that are the three phases of the system recorder. This chapter describes examples of actual utilization of the system recorder. How to Check the Recording Result Replay the data sampled by the recorder module and video recorded by the camera to assume the error cause, and then dig deep into it by analysis.

  • Page 64: Analysis Procedure

    Analysis procedure If a device error which is a saving trigger of the recorder module turns on, the error cause is determined from four causes that are the conditions of turning on the device error. As an example, a failed product arrival is used here. Then, check the device/ label value which is the cause of the error occurrence.
  • Page 65 Synchronous playback of GX Works3 and GX LogViewer Check which one of the four error causes has caused the error. Operating procedure Start the offline monitoring. (Page 51 OFFLINE MONITOR FUNCTION) Double-click "File Saving Trigger Establishment" in the event history to open the program of the file saving trigger establishment condition.
  • Page 66 Check the turning on of the device error in the waveform data. When the device error turns on, the failed product arrival turns on. Move the red cursor in GX LogViewer to the position where the failed product arrival turns on. Move the red cursor.
  • Page 67 The seek bar in GX Works3 moves in synchronization with the red cursor in GX LogViewer. Check that the error cause is on in the program. Error cause turns on. It moves to the same operation position as the red cursor in GX LogViewer.
  • Page 68 Data flow analysis Analyze the device/label error which has caused the device error to inspect the error cause. Operating procedure Perform the data flow analysis based on the error cause device/label. (Page 59 DATA FLOW ANALYSIS FUNCTION) Right-click  [Dataflow Analysis] Device to be the basing point Check the execution condition to turn on the failed product arrival.
  • Page 69 Adding log markers in GX VideoViewer to GX Works3 Add log markers to the positions where the program operation is to be checked in GX VideoViewer, and synchronize the positions with the seek bar in GX Works3. Operating procedure Since it has been determined that the workpiece height real number has effects in the data flow analysis, make log marks at the positions where the workpiece heights are measured in GX VideoViewer.
  • Page 70 Open the log marker information file (*.vms). *1 When GX VideoViewer is started and the video to which log markers have been added is opened, they can be synchronized with the following procedure. [Log Marker]  [Read from GX VideoViewer] The log markers added in GX VideoViewer are added to the seek bar.
  • Page 71 Jump to a device/label Check the workpiece heights at the positions where the log markers are made. Double-click the workpiece height real number in the data flow analysis. Jump to the label in which the workpiece height read with the sensor is stored. With the buttons, perform the frame-by-frame playback of the positions where the log markers have been made.
  • Page 72 It is determined that the workpiece height at one position is a little higher than the others. 7 OPERATION EXAMPLE 7.1 How to Check the Recording Result...
  • Page 73 Layering in GX LogViewer Display the workpiece height in a waveform in GX LogViewer to check. Operating procedure Display the failed product detection threshold and workpiece height real number in waveforms in GX LogViewer. Select a device/label  Right-click  [Wave Display] Layer the waveforms of the failed product detection threshold and workpiece height real number.

  • Page 74: Appendix

    APPENDIX Appendix 1 Troubleshooting This section describes the details, causes, and corrective actions of errors which may occur. Errors in the recorder module The following shows the checking methods of errors which may occur in the recorder module and troubleshooting. Error checking method The following two checking methods of errors are provided for the recorder module.
  • Page 75 In the module diagnostics window, check the details and corrective action of the error which has occurred. ■Buffer memory Error codes can be checked with the following buffer memory areas. • Current error area (Un\G140 to 149) • Error log area (Un\G152 to 311) For details on the buffer memory, refer to the following.
  • Page 76 Although D0Z0 = D100 is set here, D100 is not sampled automatically as well. To sample D100, describe D100 in the program or set D100 in "Device Individual Specification" of "Device/Label Sampling Setting". [Recording Setting]  [Device/Label Sampling Setting]  [Device Individual Specification] APPX Appendix 1 Troubleshooting...

  • Page 77: Errors Related To Camera Recording

    Errors related to camera recording The following shows the checking method of errors which may occur in use of the camera recording package and troubleshooting. Error checking method Error codes are output from o_uErrId which is an output label of the FB. Connect a device/label to the output label, and check the output values.
  • Page 78 Troubleshooting by symptom For troubleshooting related to each symptom, refer to the following. Camera Recording Package User's Manual ■Unable to connect to the general-purpose personal computer (Windows10) Check if a shared folder is created in the general-purpose personal computer (Windows10). Operating procedure Create a new folder, and open its properties.
  • Page 79 Select "Share this folder", and click [Permissions]. Select "Full Control", and click the [OK] button. APPX Appendix 1 Troubleshooting...

  • Page 80: Appendix 2 Event History Function (Saving Device/Label Operations)

    Appendix 2 Event History Function (Saving Device/ Label Operations) If "Save Device/Label Operations" is set in the event history setting of the CPU parameter, the event history is saved when a device/label operation is performed from an external device. It is automatically set to "Save" when the recorder module is added to the system configuration and the parameters are confirmed.
  • Page 81 MEMO APPX Appendix 2 Event History Function (Saving Device/Label Operations)

  • Page 82: Relevant Manuals

    System configuration, parameter settings, and online operations of GX Works3 [SH-081215ENG] MELSEC iQ-R Module Configuration Manual Combinations of the available MELSEC iQ-R series modules, common information on the installation/ [SH-081262ENG] wiring in the system configuration, and specifications of the power supply module, base unit, SD...

  • Page 83: Revisions

    Japanese manual number: L-08728-D This document confers no industrial property rights or any rights of any other kind, nor does it confer any patent licenses. Mitsubishi Electric Corporation cannot be held responsible for any problems involving industrial property rights which may occur as a result of using the contents noted in this document.
  • Page 84 L(NA)08732ENG-B 2011(CDS)

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