Mitsubishi fx programmable logic controllers applications and programming

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John Ridley

Mitsubishi FX

Programmable Logic Controllers

Applications and Programming

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Mitsubishi FX Programmable Logic Controllers

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Newnes

An imprint of Elsevier

Linacre House, Jordan Hill, Oxford OX2 8DP

200 Wheeler Road, Burlington, MA 01803

First published 1997

Second edition 2004

The right of John Ridley to be identified as the author of this work has been

asserted in accordance with the Copyright, Designs and Patents Act 1988

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To my wife Greta Without her continual support, I would never have completed this work

In Memory

This book is dedicated to the memory of Danny Bohane

of Honda of the UK Manufacturing Ltd Swindon,

who died aged 42, June 2001

His teaching of PLC fault-finding techniques,

I and many others will never forget

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Contents

Preface

Acknowledgements

Resources

Glossary

1 Introduction to PLCs

1.1 Basic PLC units

1.2 Comparison of PLC and RELAY systems

1.3 PLC software

1.4 Gx-Developer software

1.5 Hardware configuration

1.6 Base unit, extension units and extension blocks

1.7 PLC voltage supplies

1.8 Smaller FX2N PLCs

19 Larger FX2N PLCs

1.10 5 VDC supply

1.11 Special unit power supply requirements

1.12 Part number

1.13 Serial Number

1.14 PLC inputs

1.15 AC inputs

1.16 PLC outputs

1.17 Source-sink inputs

1.18 The source/sink — S/S connection

1.19 Source inputs — block diagram

1.20 Sink inputs — block diagram

1.21 Proximity sensors

1.22 S/S terminal configurations

1.23 PLC ladder diagram symbols

1.24 PLC address ranges

1.25 Basic operation of a PLC system

1.26 Block diagram — basic operation of a PLC system

1.27 Principle of operation

2 Gx-Developer — startup procedure

2.1 Opening a new project

2.2 Display settings - Zoom

2.3 Ladder diagram numbers

2.4 Project data list

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XXI

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Vill

3

Contents

Producing a ladder diagram

3.1 PLC program —- FLASH1

3.2 Entering a ladder diagram

3.3 Conversion to an instruction program

3.4 Saving the project

3.5 Program error check

3.6 Instruction programming

3.7 Program search

Modifications to an existing project

4.1 Copying a project

4.2 Modification of the ladder diagram FLASH2

4.3 Modification details

4.4 Deleting

Serial transfer of programs

5.1 Downloading a project to a PLC unit

5.2 Executing the project

5.3 Reducing the number of steps transferred to the PLC

5.4 Communication setup

5.5 System image

5.6 Change of communications port

5.7 Verification

5.8 Uploading a project from a PLC

Monitoring

6.1 Ladder diagram monitoring

6.2 Entry data monitoring

6.3 Combined ladder and entry data monitoring

Basic PLC programs

7.1 Traffic light controller - TRAF1

7.2 Furnace temperature controller - FURNI

7.3 Interlock circuit - INTLK1

7.4 Latch relays

7.5 Counters

7.6 Online programming

7.7 Batch counter - BATCH]

7.8 Assignment - BATCH2

7.9 Master control - MCI

PLC sequence controller

8.1 Sequence function chart — SFC

8.2 Ladder diagram - PNEUI

8.3 Simulation - PNEU1

8.4 Pneumatic panel operation

8.5 Forced input/output

8.6 Assignment —- PNEU2

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Zo

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Free line drawing

9.1 Inserting an output in parallel with an existing output

9.2 Delete free line drawing

Safety

10.1 Emergency stop requirements

10.2 Safety relay specification

10.3 Emergency stop circuit - PNEU1

10.4 Safety relay — fault conditions

10.5 System start-up check

Documentation

11.1 Comments

11.2 Statements

11.3 Display of comments and statements

11.4 Comment display — 15/16 character format

11.5 Comment display - 32 character format

11.6 Notes

11.7 Segment/note — block edit

11.8 Ladder diagram search using statements

11.9 Change of colour display

11.10 Display of comments, statements and notes

11.11 Printouts

11.12 Multiple printing

11.13 Saving comments in the PLC

Entry ladder monitoring

12.1 Ladder diagram —- PNEU1

12.2 Principle of operation — entry ladder monitoring

12.3 Deleting the entry ladder monitor diagram

Converting a MEDOC project to Gx-Developer

13.1 Importing a MEDOC file into Gx-Developer

Change of PLC type

Diagnostic fault finding

15.1 CPU errors

15.2 Battery error

15.3 Program errors

15.4 Help display — program errors

15.5 Program error check

Special M coils

16.1 Device batch monitoring

16.2 Option setup

16.3 Monitoring the X inputs

Contents 1X

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x Contents

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Set—reset programming

17.1

l72

17.3

17.4

17.5

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Trace

18.1

18.2

18.3

18.4

18.5

18.6

18.7

18.8

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18.10

18.11

18.12

18.13

18.14

PNEU4

Sequence of operation — automatic cycle

Sequence function chart - PNEU4

Ladder diagram - PNEU4

Principle of operation

Simulation and monitoring procedure

Monitoring PNEU4

Principle of operation

Ladder diagram — PNEU4

Trace setup procedure

Trace data

Trace conditions

Transfer Trace data to PLC

Saving the Trace setup data

Reading the Trace setup data from file

Start Trace operation

Start trigger — X0

Obtaining the Trace waveforms

Trace results

Measuring the time delay — TO

Calculation of elapsed time

Data registers

19.1

19.2

19.3

19.4

Number representation — binary/decimal

Converting a binary number to its decimal equivalent

Binary numbers and binary coded decimal

Advanced programming instructions

Introduction to programs using data registers

20.1

20.2

20.3

20.4

20.5

Binary counter - COUNT3

BCD counter - COUNT4

Multiplication program - MATHS 1

RPM counter —- REV1

Timing control of a bakery mixer - MIXER]

Ladder logic tester

21.1

21.2

21.3

21.4

21.5

21.6

21.7

Introduction

Program execution

Input simulation

Device memory monitor

Timing charts

Producing the timing chart waveforms

Resetting the timing chart display

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21.15

21.16

21.17

Saving the setup details

L/O system settings

Procedure — I/O system setting

Entering the Conditions and Input No settings

Executing the I/O system

Resetting a data register using the I/O system

LLT2 modification

Simulating PNEU1 using ladder logic tester

PNEUI procedure using ladder logic tester

Monitoring procedure

Bi-directional counters

22.1 Ladder diagram - COUNTS

22.2 Special memory coils M8200-M8234

22.3 Principle of operation - COUNTS

22.4 Operating procedure

22.5 Monitoring -COUNTS5

High-speed counters

23.1 Introduction

23.2 Types of high-speed counters

23.3 FX range of high-speed counters

23.4 High-speed counter inputs

23.5 Up/down counting

23.6 Selecting the high-speed counter

23.7 Maximum total counting frequency

23.8 High-speed counter - HSC1

23.9 Decade divider - HSC2

23.10 Motor controller - HSC3

23.11 A/B phase counter - HSC4

Floating point numbers

24.1 Floating point number range

24.2 | Number representation

24.3 Floating point instructions

24.4 Storing floating point numbers — FLT1

24.5 Monitor - ladder diagram FLT1

24.6 Device batch monitoring

24.7 Floating point format

24.8 Obtaining the floating point value

24.9 Device batch monitoring — floating point numbers

24.10 Area of a circle - FLT2

24.11 Ladder diagram —- FLT2

24.12 Principle of operation - FLT2

24.13 Monitored results - FLT2

24.14 Floating point — ladder logic tester

Contents XI

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