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PROGRAMMABLE CONTROLLERS MELSEC-FX FX-Series PLC Training Manual using GX-Developer FX1S FX1N FX2N FX2NC FX3U R

2 1.4 Course Description LESSON 1 - Introduction to the Course This is a brief introduction to the course, and a breakdown of the lesson topics. I

92 13.14 TO/FROM Instructions The different types of SFMs were discussed earlier in the lesson. These modules increase the capabilities of the PLC

93 13.15 EXERCISE FX2N-5A Module Access The FX3U demo cases have installed an FX2N-5A analog module. Write the TO/FROM instructions required to

94 WSFL – Word Shift Left WSFR – Word Shift Right The Word Shift Left and Word Shift Right commands will move a word (or multiple words) of data in t

95 13.18 Program Flow Control By default the PLC program processes top to bottom and left to right. At the beginning of the program, the actual i

96 CALL – Call Subroutine SRET – Subroutine Return FEND – Main Routine Program End The call subroutine command allows the execution of a section of c

97 LESSON 14 – Diagnostic Devices No programmer is perfect, and no PLC is going to last forever. Fortunately, the FX-series PLC line has a number of

98 14.2 Special D Registers The addresses D8000 and above are reserved for system use. In the FX1S/1N/2N/2NC, the range is D8000-D8255. In the FX3

99 This circuit stores the error code and error step. If the D registers have been declared to be latched registers, or the registers are in the rang

100 TZCP – Time Zone Compare The TZCP time compare instruction will compare the hours, minutes, and seconds as set in the parameters to 2 sets of 3 c

101 14.6 GX-Developer Diagnostics Much of what has been discussed was necessary to troubleshoot programs in pre GX-Developer days. This information

3 LESSON 13 - Applied Instructions This lesson covers all special processing instructions: data manipulation instructions such as MOV, arithmetic inst

102 Error Number 6705 is the error that appears in D8067. Step 4 is the step where the error occurs and is stored in D8069. The message Operation Er

103 Find Device is used to find a device address regardless of the instruction. It will search the entire program for a particular address. There

104 Find Contact or Coil will search the program for an address used as either a contact or a coil. In the first window, select contact or coil. The

105 Replace Instruction will change one instruction type to another. The earlier instruction is the type of instruction to replace, and the new instr

106 Cross reference information can be displayed in one of two ways. One option is the Cross Reference List, which is a pop-up window display of the

107 List of Used Devices The List of Used Devices will show a list of the devices used in the program. The list can be configured to show a single p

108 GX-Developer has a built-in wizard to assist in the configuration of the data trace. Settings can also be defined manually. Once the settings ar

109 LESSON 15 – Documentation & Printing The programs that have been written so far have been fairly simple, and you, the programmer have been pr

110 Important: The PLC will only hold the first 16 characters of comments. The rest of the comment will be truncated. If the programmer wants to do

111 A statement can be up to 64 characters long. Multiple statements can be attached to a single rung to provide an in-depth description of the rung’

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112 15.6 Printing GX-Developer has very flexible printing capabilities. These can be accessed by clicking on the Printer Icon on the toolbar. The pr

113 Here is the Print Dialog Box. Click on the tab for the method of printing desired.

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115 APPENDICES

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Project 10X010Y0002X011 X012Y001Y0016X013 X014Y002X01510X016 Y000 Y001Y003Y004Y00516X017 Y002Y006Y00720 END

Project 20X010 K50T0K1000T1287T0Y0009T0Y00111T128Y00213T128Y00315X011 K100T20019T200Y00421T200Y00523X012RST T20026X013 K10C030C0Y00632C0Y00734X014RST

Project 30X010INC D04X011INCP D08X012DEC D012X013DECP D016X014RST D020X015MOV K0 D026 END

Project 40X010ADD D0 D1 D108X011SUB D0 D1 D1016X012MUL D0 D1 D1024X013DIV D0 D1 D1032 END

5 LESSON 2 – FX Series Hardware Review This lesson discusses the hardware structure of the FX-Series logic controller. This includes a review of the

6 2.2 The FX Line of PLCs Each of the PLCs in this family have certain characteristics in common: 1) An integrated power supply. Most of the PLC

7 FX1N This model of PLC is one of Mitsubishi’s most advanced. It provides the midrange number of I/O points similar to the FX0N, but has far more c

8 2.3 Hardware Components Main Units The main unit contains the CPU that provides the processing power that reads the inputs, solves

9 Powered Extension Units As was mentioned previously, the FX3U is very expandable. One way to increase I/O is through the use of power

10 Unpowered Extension Blocks The second way to expand the I/O of the FX3U system is through the use of unpowered extension blocks. These do not hav

11 SINK or SOURCE logic refers to the voltage level that will cause the input to become active. SINK logic: the input becomes active when connected t

12 The input trigger levels vary, depending on the module type. Generally, the input becomes active at the 2/3 level, then the input becomes inactive

13 There are 3 different output types … • Relay Outputs • Triac Outputs • Transistor Outputs RELAY OUTPUTS Relays are dry contacts, so whatever

14 2.6 Special Function Modules All of the modules that have been discussed thus far have been DISCRETE I/O modules. The inputs or outputs are eit

15 Temperature Input Modules These modules are similar to analog input modules, except for the type of input devices which can be connected. These m

16 Single Axis Positioning Modules Also known as the pulse generator, the FX2N-1PG module creates a pulse train output that can be used for motion co

17 FX3U Adapter Bus High Speed Pulse Output Module The FX3U-2HSY-ADP module connects to the FX3U’s left side expansion bus, and provides high speed p

18 The FX3U-232ADP (pictured left) can be connected to the left side of the PLC through the left side expansion bus. This module requires special pro

19 USB Option Board – FX3U-USB-BD With recent updates to personal computers, a computer with a serial port is becoming rarer. This option board will

20 I/O Link – FX2N-16LNK-M I/O link is actually a distributed I/O system for Mitsubishi FX series PLCs. I/O modules can be placed at up to 200m from

21 Ethernet Interface Modules – FX2NC-ENET-ADP & FX3U-ENET Ethernet is the industry standard for computer-to-computer networking. Ethernet is b

Revisions * The manual number is noted at the lower left corner of the front cover. Print Date Manual Number Revision 12/8/00 Rev * - Created ne

22 How to compute power drain of the power supply As has been stated before, the power supply can only support a certain number of extension block an

23 TABLE 1: FX3U (16 or 32 I/O units) TABLE 2: FX3U (48 I/O or larger) TABLE 3: FX2N-32E* TABLE 4: FX2N-48E*

24 TABLE 5: 24VDC and 5VDC Supply Capacities FX3U CPU Units (AC Powered) FX3U CPU Units (DC Powered)

25 FX2N Powered Extension Units TABLE 6: Expansion Devices FX3U Option Boards FX3U Adapter Bus Modules

26 FX2N Unpowered Extension Blocks Special Function Modules

27 Special Function Modules (Continued) FX3U Display Module

28 Worksheet for Exercise 2.12

29 2.12 EXERCISE Power Supply Calculation Using the worksheet on the previous page, combined with the preceding tables, use the steps as discuss

30 2.13 Memory Types The FX3U comes with enough internal RAM to hold a program of 64K steps. The 64K memory in the FX3U is NOT expandable. The FX2

31 FLROM (Flash ROM) FLROM is permanent memory also; the program is retained with no battery required. FLROM operates similarly to EEPROM, as it is e

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33 LESSON 3 – Programming Equipment This lesson discusses the hardware and software requirements to program a PLC. The student will also be shown ho

34 features, as well as the ability to easily communicate over networks. It also has import capabilities to bring in programs written in older softwa

35 It is very important that the prompts are read and responded to, because this is the only opportunity to install the Import From MELSEC MEDOC featu

36 Local Device Monitor A new feature to GX-Developer, this monitor allows the programmer to monitor the states of local devices (used with the QCPU o

37 3.4 File Format 3.5 Hardware Connection The SC09 cable is used to connect the PLC to a personal computer for program development. The circular

38 If the PC does not have an RS232 serial port, there are a couple of options available. • On the FX3U series PLC, you can install an FX3U-USB-BD

39 LESSON 4 – Numbering Systems The PLC uses several numbering systems besides the Base 10 decimal system. An understanding of these other systems i

40 To convert from binary to decimal, just add the bit values of the bits that are set to ‘1’. Binary Word Decimal Value 000

41 4.3 Octal Numbers Octal is a Base 8 numbering system, meaning there are 8 possible values. The numbers for the octal system are 0 ~ 7. In

i Introduction Thank you for purchasing the Mitsubishi FX-Series Programmable Logic Controller. Before using the equipment, please read this manual c

42 Bit Value 8 4 2 1 8 4 2 1

43 4.5 EXERCISE Number Systems Conversion In this exercise, convert the following numbers to the given number system. n Convert decimal 2 to

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45 LESSON 5 – Numeric Data in PLCs Most PLC applications will require the handling of data, whether manipulating counter and timer values, reading da

46 The PLC uses a numbering format known as two’s complement to display negative numbers. Two’s complement is easy to calculate: n Change all 1’s

47 5.2 Decimal Handling As mentioned above, the default method for handling decimals is to drop them. This restriction can be avoided through the

48 It is not possible to monitor and interpret the values in D and D+1 for Floating Point format in the same way that Scientific Notation can be mon

49 LESSON 6 – System Devices To write a program for a PLC, it is necessary to be familiar with the devices that are used in the instructions. An over

50 If STL programming is utilized in conjunction with the IST instruction (Initial State) causes certain state relays to have special operations. 2

51 D – Data Registers D devices are data registers. Data registers can be used for any purpose. All data registers are 16 bit, meaning the limits o

ii LESSON 5 – Numeric Data in PLCs 5.1 Integer (16/32 Bit) ... 45 5

52 V and Z – Index Registers Index registers are indicated by the symbols V and Z. V and Z can both be used for 16 bit applications, while only Z ca

53 LESSON 7 - Addressing Controlling and monitoring I/O in a PLC program requires knowledge of the address of the point to be controlled. The same a

54 There are 4 different types of modules available. • Analog I/O Modules (maximum 4 per CPU) • High Speed Pulse Input Module (maximum 2 per CPU) •

55 7.3 Example FX3U-48MR/ES X00-X07, X10-X17, X20-X27 Y00-Y07, Y10-Y17, Y20-Y27 Left Side Bus: from the CPU out to the left FX3U-232-BD boar

56 7.4 EXERCISE PLC Addressing 1) A PLC system consists of an FX3U-64MR (32 I/ 32 O), 1 FX3U-4AD-ADP, an 8 point input module, 2 16-point outpu

57 LESSON 8 – Demo Kit Layout Now that all the necessary background has been covered, it is time to take out and set up the hardware. The following

58 8.2 Indicator Lights The PLC has indicator LEDs for its inputs and outputs. These lights are on the right side of the main unit, one set for inpu

59 LESSON 9 – PLC Instruction Types To write a program for a PLC, it is necessary to be familiar with the instructions that make up the PLC Instructi

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61 LESSON 10 – Basic Instructions Basic instructions are bit control instructions, typically they make up 90% of the ladder program. They are used t

iii LESSON 12 – Timers and Counters 12.1 Timers...

62 For example, a light switch is usually in the off position (non-actuated), no current is flowing (the switch is open) until someone turns it on (a

63 AND/OR conditions can be combined to create complex rungs of logic. Note: A rung must have an input condition, and an output to be a complete c

64 Another method for pulsing contacts is the rising edge and falling edge pulse bits. These bits activate only for one scan similar to the PLS a

65 10.4 EXERCISE Ladder Basics 1) X1 turns on and sets Y3. What happens to Y3 when X1 turns off? 2) What type of symbol would you use to rep

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67 LESSON 11 – Develop & Edit Programs Now is the time to put to work some of the knowledge that has been covered so far. In this section, we wi

68 The dark gray area is the workspace where the ladder logic will appear. Most of the toolbars that are open are but rarely used. These can be clo

69 11.3 Editing the Ladder We will now enter a basic ladder logic program. Follow the steps below to create this simple ladder program. 1) Click

70 This is the ladder logic diagram written out in instruction list, which is the program format that the PLC actually understands. Ladder can be dis

71 Special Shortcut It may appear that this very small program takes a long time to download. This is because no matter how many ladder logic steps

iv LESSON 15 – Documentation and Printing 15.1 Comments ...

72 11.6 Monitor the Program Operation It is possible to view what’s happening in the program, and to check the states of program bits, in GX-Develop

73 11.7 Forcing Bits and Changing Registers It can often be helpful to run sections of PLC code while writing a program. This allows the programmer

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75 LESSON 12 – Timers and Counters Timers and counters are a standard part of a PLC program. This section will cover the various types of timers and

76 Presets Preset is the length of time the timer runs before finishing. The preset indicates units of time bases. Thus T0 with a value of 50 runs

77 16 bit counters Presets Presets are the number of times the rung driving the counter has to go through a FALSE to TRUE state transition before t

78 32 bit counters Presets Presets are the number of times the rung driving the counter has to go through a FALSE to TRUE state transition before t

79 12.3 Program Examples Start a new program and enter the following timer delay circuit. When developing logic, try to use the words AND and

80 Here is a Flip-flop circuit. Initially the T3 contact conducts, T4 coil counts up to 5 seconds. When T3 completes, T4 coil comes on. T4 contac

81 A quick calculation shows that the longest time duration that can be handled by a timer is (32,767 x .1 sec / 60) = 54.36 minutes. What happens if

1 LESSON 1 – Introduction & Overview Welcome to the FX-Series programmers training course. This course is intended for designers and control engi

82 The HOUR instruction is a built-in hour meter. The function times the number of seconds the function has been active. It allows the operator to s

83 LESSON 13 – Applied Instructions These instructions are the ‘specialist’ instructions of the FX line. These instructions allow the PLC to perform

84 Applied instructions by default are 16 bit instructions. If 32 bit data manipulation is desired, it is necessary to add a “D” to the front of the

85 BMOV – Block Move The BMOV block move command moves data 3 words of data starting from the source (D1) to the 3 words of data starting at the dest

86 CMP – Compare DCMP – 32-Bit Compare DECMP – Floating Point Compare The CMP compare instruction must be placed at the end of the rung. Its destin

87 INLINE COMPARISONS Unlike all the function blocks discussed so far, the inline compare instructions can be placed anywhere within the rung. They

88 13.4 EXERCISE Parking Lot Write a program for the following parking lot control application: X10 indicates a car coming in X11 indicates a car

89 13.7 Increment and Decrement Instructions INC – Increment DINC – 32-Bit Increment DEC – Decrement DDEC – 32-Bit Decrement The increment and decr

90 Note how all 32-bit commands were prefixed with a D. All floating point commands are also prefixed with a D since they operate on 32-bit numbers,

91 While it is possible to use SET, RESET and the comparison instructions with high speed counters, these instructions are scan dependent and limit th