Equipment Maintenance・2024
Replacing a 20-Year-Old A Series PLC with iQ-R
A Mitsubishi A series PLC that had run for more than 20 years was long discontinued. We simulated the program offline, converted it to iQ-R and updated the line in stages, finishing the on-site work in 7 days.
CHALLENGE
Challenge
The customer had an A series PLC (APLC) that had been running for more than 20 years. It was long discontinued, spare parts were hard to find, and a failure could have meant a long production stop. So we replaced the whole system with an iQ-R PLC.
SOLUTION
Solution
We first inspected the PLC and I/O modules on site, made a complete backup of the program and parameters, and compiled an I/O mapping table. We then proposed a phased replacement plan using current models, carried out during the annual shutdown.
EQUIPMENT
Equipment and Technology
- Mitsubishi A series PLC replaced with iQ-R
- GX Works3
- Servo, analog and high-speed counter modules
- I/O mapping table
RESULTS
Results
- Program simulated offline before conversion
- Servo, analog and high-speed counter code all rewritten
- On-site work completed in 7 days
The original APLC program was simulated offline first, then converted to the iQ-R PLC in GX Works3. The parameters and code for the existing servo control (flying shear), analog control (line speed) and high-speed counters (measuring wheel, encoders and so on) were all rewritten in the current syntax. The update was then rolled out one small part at a time as planned, to avoid a flood of errors from a single big cutover. The on-site work took about 7 days.
GALLERY
