Mitsubishi FX Programmable Logic Controllers This Page is Intentionally Left Blank Mitsubishi FX Programmable Logic Controllers Applications and Programming JOHN RIDLEY Diploma in Electrical Engineering, C.Eng., MIEE. PLC Consultant MFI Manufacturing Runcorn Cheshire AMSTERDAM • BOSTON • HEIDELBERG • LONDON NEW YORK • OXFORD • PARIS • SAN DIEGO SAN FRANCISCO • SINGAPORE • SYDNEY • TOKYO Newnes is an imprint of Elsevier Newnes AnimprintofElsevier LinacreHouse,JordanHill,OxfordOX28DP 200WheelerRoad,Burlington,MA01803 Firstpublished2004 Copyrightª2004,JohnRidley.Allrightsreserved TherightofJohnRidleytobeidentifiedastheauthorofthisworkhasbeen assertedinaccordancewiththeCopyright,DesignsandPatentsAct1988 Nopartofthispublicationmaybereproducedinanymaterialform(including photocopyingorstoringinanymediumbyelectronicmeansandwhether ornottransientlyorincidentallytosomeotheruseofthispublication)without thewrittenpermissionofthecopyrightholderexceptinaccordancewiththe provisionsoftheCopyright,DesignsandPatentsAct1988orunderthetermsof alicenceissuedbytheCopyrightLicensingAgencyLtd,90TottenhamCourtRoad, London,EnglandW1T4LP.Applicationsforthecopyrightholder’swritten permissiontoreproduceanypartofthispublicationshouldbeaddressed tothepublisher PermissionsmaybesoughtdirectlyfromElsevier’sScience&TechnologyRights DepartmentinOxford,UK:phone:(þ44)1865843830,fax:(þ44)1865853333, e-mail:permissions@elsevier.co.uk.Youmayalsocompleteyourrequeston-linevia theElsevierhomepage(http://www.elsevier.com),byselecting‘CustomerSupport’ andthen‘ObtainingPermissions’ BritishLibraryCataloguinginPublicationData AcataloguerecordforthisbookisavailablefromtheBritishLibrary LibraryofCongressCataloguinginPublicationData AcataloguerecordforthisbookisavailablefromtheLibraryofCongress ISBN 0750656794 ForinformationonallNewnespublications visitourwebsiteathttp://books.elsevier.com TypesetbyIntegraSoftwareServicesPvt.Ltd,Pondicherry,India www.integra-india.com PrintedandboundinGreatBritain To my wife Greta Without hercontinual support, Iwould never have completedthis work. In Memory This bookis dedicated tothe memoryof Danny Bohane of Honda of theUK Manufacturing Ltd.Swindon, who died aged 42,June2001. His teaching of PLC fault-finding techniques, Iand manyotherswill neverforget. This Page is Intentionally Left Blank Contents Preface xv Acknowledgements xvii Resources xix Glossary xxi 1 Introductionto PLCs 1 1.1 Basic PLC units 1 1.2 Comparison of PLC and RELAY systems 2 1.3 PLC software 2 1.4 Gx-Developer software 3 1.5 Hardwareconfiguration 3 1.6 Base unit, extension units and extension blocks 4 1.7 PLC voltagesupplies 4 1.8 Smaller FX2N PLCs 4 1.9 Larger FX2N PLCs 6 1.10 5 VDC supply 6 1.11 Special unit power supply requirements 6 1.12 Part number 7 1.13 Serial Number 7 1.14 PLC inputs 8 1.15 AC inputs 8 1.16 PLC outputs 9 1.17 Source–sinkinputs 10 1.18 The source/sink– S/S connection 11 1.19 Source inputs– block diagram 11 1.20 Sink inputs –block diagram 12 1.21 Proximity sensors 12 1.22 S/S terminal configurations 13 1.23 PLC ladder diagramsymbols 13 1.24 PLC address ranges 15 1.25 Basic operation ofa PLC system 15 1.26 Block diagram –basic operation ofa PLC system 16 1.27 Principleof operation 17 2 Gx-Developer– startupprocedure 18 2.1 Opening anewproject 19 2.2 Displaysettings – Zoom 19 2.3 Ladderdiagram numbers 22 2.4 Project datalist 22 viii Contents 3 Producinga ladder diagram 24 3.1 PLC program –FLASH1 24 3.2 Entering aladderdiagram 25 3.3 Conversionto an instruction program 27 3.4 Saving theproject 28 3.5 Program error check 28 3.6 Instruction programming 29 3.7 Program search 31 4 Modifications toan existingproject 40 4.1 Copyinga project 40 4.2 Modification of theladder diagram FLASH2 42 4.3 Modification details 42 4.4 Deleting 50 5 Serial transfer ofprograms 55 5.1 Downloading a project toa PLC unit 55 5.2 Executing theproject 56 5.3 ReducingthenumberofstepstransferredtothePLC 57 5.4 Communication setup 58 5.5 System image 59 5.6 Change ofcommunications port 60 5.7 Verification 62 5.8 Uploading aproject from a PLC 63 6 Monitoring 66 6.1 Ladderdiagram monitoring 66 6.2 Entry datamonitoring 67 6.3 Combined ladder and entrydata monitoring 70 7 BasicPLC programs 71 7.1 Traffic light controller – TRAF1 71 7.2 Furnacetemperature controller –FURN1 74 7.3 Interlock circuit– INTLK1 78 7.4 Latch relays 80 7.5 Counters 81 7.6 Online programming 84 7.7 Batch counter – BATCH1 86 7.8 Assignment –BATCH2 87 7.9 Mastercontrol – MC1 87 8 PLC sequencecontroller 91 8.1 Sequencefunction chart –SFC 92 8.2 Ladderdiagram –PNEU1 93 8.3 Simulation – PNEU1 97 8.4 Pneumatic panel operation 98 8.5 Forced input/output 101 8.6 Assignment –PNEU2 104 Contents ix 9 Free line drawing 105 9.1 Inserting an output inparallel withan existing output 108 9.2 Delete free line drawing 109 10 Safety 111 10.1 Emergency stop requirements 111 10.2 Safety relay specification 112 10.3 Emergency stop circuit –PNEU1 113 10.4 Safety relay –fault conditions 114 10.5 System start-upcheck 115 11 Documentation 116 11.1 Comments 117 11.2 Statements 123 11.3 Displayof commentsand statements 124 11.4 Comment display– 15/16 characterformat 125 11.5 Comment display– 32 characterformat 128 11.6 Notes 130 11.7 Segment/note – block edit 132 11.8 Ladderdiagram search usingstatements 133 11.9 Change ofcolourdisplay 134 11.10 Displayof comments,statementsand notes 135 11.11 Printouts 137 11.12 Multipleprinting 141 11.13 Saving commentsin the PLC 146 12 Entry ladder monitoring 151 12.1 Ladderdiagram –PNEU1 152 12.2 Principleof operation –entryladder monitoring 153 12.3 Deleting theentryladder monitordiagram 156 13 Convertinga MEDOC project toGx-Developer 157 13.1 Importinga MEDOC file into Gx-Developer 157 14 Change of PLC type 162 15 Diagnosticfaultfinding 165 15.1 CPU errors 165 15.2 Batteryerror 166 15.3 Program errors 166 15.4 Help display – program errors 168 15.5 Program error check 169 16 Special M coils 171 16.1 Device batch monitoring 171 16.2 Option setup 173 16.3 Monitoring theX inputs 174
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