Mitsubishi FX Programmable Logic Controllers: Applications and Programming

421 Pages·2004·4.13 MB·English

Mitsubishi FX Programmable Logic Controllers
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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
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Firstpublished2004
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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.
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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