Mitsubishi Electric MELSEC-Q QnPHCPU Owner's manual

A - 1 A - 1
•SAFETY CAUTIONS •
(You must read these cautions before using the product)
In connection with the use of this product, in addition to carefully reading both this manual and the related
manuals indicated in this manual, it is also essential to pay due attention to safety and handle the product
correctly.
The safety cautions given here apply to this product in isolation. For information on the safety of the PLC
system as a whole, refer to the CPU module User's Manual.
Store this manual carefully in a place where it is accessible for reference whenever necessary, and
forward a copy of the manual to the end user.

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REVISIONS
* The manual number is given on the bottom left of the back cover.
Print Date * Manual Number Revision
Apr., 2002 SH (NA)-080316E-A First edition
Jun., 2004 SH (NA)-080316E-B Manual name change
QnPHCPU Programming Manual (Process Control Instructions)
QnPHCPU/QnPRHCPU Programming Manual (Process Control
Instructions)
Term change
DVL: Change rate limit value Deviation limit value
Partial addition
About Manuals, Section 2.2.1, 2.2.3, 3.3.5, Chapter 7, Section 8.5, 9.18,
9.21, 10.1, 10.2, Appendix 2.3, Appendix 2.7
Addition
Generic terms and abbreviations used in this manual
May, 2005 SH (NA)-080316E-C Correction
CONTETNTS, Section 3.2, 6.2.3, 8.2, 8.5, 9.1, 9.2, 9.3, 9.4, 9.5, 9.8,
10.1, 10.2
May, 2008 SH (NA)-080316E-D Revision due to the addition of Process CPU
Addition module
Q02PHCPU, Q06PHCPU
Partial correction
GENERIC TERM AND ABBREVIATIONS USED IN THIS MANUAL,
Section 9.18
Japanese Manual Version SH-080265-D
This manual confers no industrial property rights or any rights of any other kind, nor does it confer any patent
licenses. Mitsubishi Electric Corporation cannot be held responsible for any problems involving industrial property
rights which may occur as a result of using the contents noted in this manual.
©2002 MITSUBISHI ELECTRIC CORPORATION

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INTRODUCTION
Thank you for purchasing the Mitsubishi MELSEC-Q Series (Q mode) PLC.
Before using the product, please read this manual carefully to develop full familiarity with the functions and
performance of the Q Series (Q mode) PLC you have purchased, so as to ensure correct use.
CONTENTS
SAFETY CAUTIONS.....................................................................................................................................A- 1
REVISIONS ...................................................................................................................................................A- 2
CONTENTS...................................................................................................................................................A- 3
ABOUT MANUALS........................................................................................................................................A- 7
GENERIC TERM AND ABBREVIATIONS USED IN THIS MANUAL .........................................................A- 7
1. OVERVIEW 1 - 1 to 1 - 9
1.1 Features.................................................................................................................................................. 1 - 1
1.2 PID Control Overview............................................................................................................................. 1 - 4
1.3 Forward Oprration and Reverse Operation ........................................................................................... 1 - 5
1.4 PID Control ............................................................................................................................................. 1 - 6
1.4.1 Proportional operation (P operation) ............................................................................................... 1 - 6
1.4.2 Integral operation (I operation) ........................................................................................................ 1 - 7
1.4.3 Derivative operation (D operation) .................................................................................................. 1 - 8
1.4.4 PID operation................................................................................................................................... 1 - 9
2. STRUCTURE AND COMBINATIONS OF PROCESS CONTROL INSTRUCTIONS 2 - 1 to 2 - 6
2.1 Instruction Configuration ........................................................................................................................ 2 - 1
2.2 Method for Specifying the Data in a Device........................................................................................... 2 - 2
2.2.1 For bit data....................................................................................................................................... 2 - 2
2.2.2 For word (16-bit) data ...................................................................................................................... 2 - 2
2.2.3 Double word (32-bit) data ................................................................................................................ 2 - 3
2.2.4 For real number data (floating-point data) ...................................................................................... 2 - 3
2.2.5 Process control instruction operation error ..................................................................................... 2 - 4
2.2.6 Instruction execution conditions ...................................................................................................... 2 - 4
2.2.7 Number of steps .............................................................................................................................. 2 - 4
2.2.8 Index qualification ............................................................................................................................ 2 - 5
2.3 Basic Loop Types Available by Combinations of Process Control Instructions.................................... 2 - 5
3. DATA USED FOR PROCESS CONTROL INSTRUCTIONS AND HOW TO SPECIFY DATA 3 - 1 to 3 - 9
3.1 Process Control Instructions and Data Configuration ........................................................................... 3 - 1
3.2 Local Work Memory ............................................................................................................................... 3 - 3
3.3 Data Used for Process Control Instructions .......................................................................................... 3 - 4
3.3.1 Loop memory................................................................................................................................... 3 - 4
3.3.2 Input data ......................................................................................................................................... 3 - 5
3.3.3 Block memory.................................................................................................................................. 3 - 6
3.3.4 Operation constant .......................................................................................................................... 3 - 6
3.3.5 Loop tag memory allocation contents ............................................................................................. 3 - 7

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4. HOW TO EXECUTE PROCESS CONTROL INSTRUCTIONS 4 - 1 to 4 - 2
4.1 Execution Time and Control Cycle......................................................................................................... 4 - 1
4.2 Concept of Program ............................................................................................................................... 4 - 2
5. EXECUTION CONDITION SWITCHING AND FUNCTIONS 5 - 1 to 5 - 3
5.1 Execution Condition Switching............................................................................................................... 5 - 1
5.1.1 Loop RUN/STOP ............................................................................................................................. 5 - 1
5.2 Functions ................................................................................................................................................ 5 - 2
5.2.1 Tracking function ............................................................................................................................. 5 - 2
5.2.2 Cascade loop tracking..................................................................................................................... 5 - 2
5.2.3 Loop selector tracking ..................................................................................................................... 5 - 3
6. INSTRUCTION LIST 6 - 1 to 6 - 6
6.1 How to Read the Instruction List Table .................................................................................................. 6 - 1
6.2 Functions ................................................................................................................................................ 6 - 2
6.2.1 I/O control instruction....................................................................................................................... 6 - 2
6.2.2 Control operation instruction............................................................................................................ 6 - 3
6.2.3 Compensation operation instruction................................................................................................ 6 - 5
6.2.4 Arithmetic operation instruction ....................................................................................................... 6 - 5
6.2.5 Comparison operation instruction ................................................................................................... 6 - 6
6.2.6 Auto tuning instruction ..................................................................................................................... 6 - 6
7. HOW TO READ INSTRUCTIONS 7 - 1 to 7 - 4
8. I/O CONTROL INSTRUCTIONS 8 - 1 to 8 - 36
8.1 Analog Input Processing (S.IN).............................................................................................................. 8 - 1
8.2 Output Processing-1 with Mode Switching (S.OUT1) ........................................................................... 8 - 6
8.3 Output Processing-2 with Mode Switching (S.OUT2) ........................................................................... 8 - 12
8.4 Manual Output (S.MOUT) ...................................................................................................................... 8 - 17
8.5 Time Proportioning (S.DUTY) ................................................................................................................ 8 - 21
8.6 Batch Counter (S.BC)............................................................................................................................. 8 - 28
8.7 Pulse Integration (S. PSUM) .................................................................................................................. 8 - 32
9. CONTROL OPERATION INSTRUCTIONS 9 - 1 to 9 -111
9.1 Basic PID (S.PID) ................................................................................................................................... 9 - 1
9.2 2-degree-of-freedom PID Control (S.2PID) ........................................................................................... 9 - 9
9.3 Position Type PID Control (S.PIDP)....................................................................................................... 9 - 17
9.4 Sample PI Control (S.SPI) ..................................................................................................................... 9 - 26
9.5 I-PD Control (S.IPD)............................................................................................................................... 9 - 33
9.6 Blend PI Control (S.BPI)......................................................................................................................... 9 - 41
9.7 Ratio (S.R) .............................................................................................................................................. 9 - 48
9.8 High/Low Limit Alarm (S.PHPL)............................................................................................................. 9 - 53
9.9 Lead-lag (S.LLAG) ................................................................................................................................. 9 - 59

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9.10 Integral (S.I) .......................................................................................................................................... 9 - 61
9.11 Derivative (S.D) .................................................................................................................................... 9 - 63
9.12 Dead Time (S.DED) ............................................................................................................................. 9 - 65
9.13 High Selector (S.HS) ............................................................................................................................ 9 - 68
9.14 Low Selector (S.LS) ............................................................................................................................. 9 - 70
9.15 Middle Value Selection (S.MID) ........................................................................................................... 9 - 72
9.16 Average Value (S.AVE)........................................................................................................................ 9 - 75
9.17 High/low Limiter (S.LIMT)..................................................................................................................... 9 - 77
9.18 Variation Rate Limiter 1 (S.VLMT1) ..................................................................................................... 9 - 79
9.19 Variation Rate Limiter 2 (S.VLMT2) ..................................................................................................... 9 - 81
9.20 2-position ON/OFF (S.ONF2) .............................................................................................................. 9 - 83
9.21 3-position ON/OFF (S.ONF3) .............................................................................................................. 9 - 89
9.22 Dead Band (S.DBND) .......................................................................................................................... 9 - 95
9.23 Program Setter (S.PGS) ...................................................................................................................... 9 - 97
9.24 Loop Selector (S. SEL)........................................................................................................................ 9 -102
9.25 Bumpless Transfer (S.BUMP) ............................................................................................................ 9 -108
9.26 Analog Memory (S.AMR) .................................................................................................................... 9 -110
10. COMPENSATION OPERATION INSTRUCTIONS 10 - 1 to 10 - 15
10.1 Function Generator (S.FG) ................................................................................................................ 10 - 1
10.2 Inverse Function Generator (S.IFG) .................................................................................................. 10 - 3
10.3 Standard Filter (S.FLT)....................................................................................................................... 10 - 5
10.4 Summation (S.SUM) .......................................................................................................................... 10 - 8
10.5 Temperature/Pressure Correction (S.TPC)....................................................................................... 10 - 10
10.6 Engineering Value Conversion (S.ENG)............................................................................................ 10 - 12
10.7 Inverse Engineering Value Conversion (S.IENG).............................................................................. 10 - 14
11. ARITHMETIC OPERATION INSTRUCTIONS 11- 1 to 11 - 12
11.1 Addition (S.ADD) ................................................................................................................................ 11 - 1
11.2 Subtraction (S.SUB) ........................................................................................................................... 11 - 3
11.3 Multiplication (S.MUL) ........................................................................................................................ 11 - 5
11.4 Division (S.DIV) .................................................................................................................................. 11 - 7
11.5 Square Root (S.SQR) ........................................................................................................................ 11 - 9
11.6 Absolute Value (S.ABS) ..................................................................................................................... 11 - 11
12. COMPARISON OPERATION INSTRUCTIONS 12- 1 to 12 - 10
12.1 Compare Greater Than (S. ) .......................................................................................................... 12 - 1
12.2 Compare Less Than (S. )............................................................................................................... 12 - 3
12.3 Compare Equal Than (S. )............................................................................................................. 12 - 5
12.4 Compare Greater Or Equal (S. )................................................................................................ 12 - 7
12.5 Compare Less Or Equal (S. ) .................................................................................................... 12 - 9
13. AUTO TUNING 13- 1 to 13 - 12
13.1 Auto Tuning Instruction (S.AT1)......................................................................................................... 13 - 4

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14. ERROR CODE 14- 1 to 14 - 2
14.1 Error Code List ................................................................................................................................... 14 - 1
APPENDICES APP - 1 to APP - 21
APPENDIX1 EXAMPLE PROGRAM.......................................................................................................APP - 1
APPENDIX 2 LOOP TAG MEMORY LIST ..............................................................................................APP - 5
2.1 PID Control (SPID), 2-degree-of-freedom PID Control (S2PID), Sample PI Control (SSPI)........APP - 5
2.2 I-PD Control (SIPD), Blend PI Control (SBPI)................................................................................APP - 7
2.3 Manual Output (SMOUT), Monitor (SMON)...................................................................................APP - 9
2.4 Manual Output with Monitor (SMWM), PIDP Control (SPIDP)......................................................APP -10
2.5 2 Position ON/OFF Control (SONF2), 3 Position ON/OFF Control (SONF3) ...............................APP -12
2.6 Batch Counter (SBC)......................................................................................................................APP -13
2.7 Ratio Control (SR) ..........................................................................................................................APP -14
APPENDIX 3 OPERATION PROCESSING TIME ..................................................................................APP -16
3.1 The Operation Processing Time of Each Instruction.....................................................................APP -16
3.2 Operation Processing Time of 2-degree-of-freedom PID Control Loop........................................APP -19
INDEX Index- 1 to Index- 3

A - 7 A - 7
ABOUT MANUALS
The manuals related to the Q/QnACPU are listed in the table below.
Please order those you require.
Related Manuals
Manual Name Manual Number
(Model Code)
QCPU User's Manual (Hardware Design, Maintenance and Inspections)
Describes the specifications of the CPU module, power supply module, base unit, expansion cables, and
memory card. (Sold separately)
SH-0800483ENG
(13JR73)
QCPU User's Manual (Function Explanation, Program Fundamentals)
This manual explains the functions, programming methods, devices and so on necessary to create programs
with the CPU module. (Sold separately)
SH-080484ENG
(13JR74)
QCPU (Q Mode)/QnACPU Programming Manual (Common Instructions)
This manual describes how to use the sequence instructions, basic instruction and application instructions.
(Sold separately)
SH-080039
(13JF58)
QCPU (Q mode)/QnACPU Programming Manual (SFC)
Describes the system configuration, performance specifications, functions, programming, debugging, and error
codes, for MELSAP3. (Sold separately)
SH-080041
(13JF60)
QCPU (Q mode) Programming Manual (MELSAP-L)
Describes the system configuration, performance specifications, functions, programming, debugging, error
codes and others of MELSAP-L. (Sold separately)
SH-080076
(13JF61)
GENERIC TERM AND ABBREVIATIONS USED IN THIS MANUAL
This manual uses the following generic terms and abbreviations unless otherwise
described.
Generic term/abbreviation Description of generic term/abbreviation
QnPHCPU Abbreviation of Q02PHCPU,Q06PHCPU,Q12PHCPU,Q25PHCPU
QnPRHCPU Abbreviation of Q12PRHCPU,Q25PRHCPU

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MEMO

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MELSEC-Q
1 OVERVIEW
1 OVERVIEW
This manual describes the process control instructions equipped for the QnPHCPU/QnPRHCPU.
1.1 Features
The process control instructions have the following features.
(1) Use of floating-point data
Capable of handling floating-point type real number data, the instructions can perform wide-
range and accurate operations.
(2) Increased efficiency of system adjustment
Micro-blocked process control instructions are combined to perform PID control.
This enables actions to be confirmed on a process control instruction basis, ensuring efficient
system adjustment.
Example) Process control instructions used to carry out 2-degree-of-freedom PID control
Process control instruction 3
(2-degree-of-freedom PID
control instruction)
Use name instruction common table.
T0
M0PLS
R0D0
FLT
R1000R200R100R0S.IN
R20R100EMOV
R1000R220R120R20
S.PHPL
R40R120EMOV
R300R1000R240R140S.2PID R40
R60R140EMOV
P1
K1
Execution command
P1CALL
T0RST
FEND
T0
M0
Normal execution
R1000R260R160R60S.OUT1
D1R160
INT
Operation constant setting
RET
Microblock
S.IN instruction
Microblock
S.PHPL instruction
Microblock
S.2PID instruction
Microblock
S.OUT1 instruction
Process control instruction 2
(High/Low Limit Alarm instruction)
Process control instruction 1
(Input instruction)
Set value (SV) Process value (PV)
Loop tag memory setting
Process control instruction 4
(Output instruction)
1

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MELSEC-Q
1 OVERVIEW
(3) Free combination of process control instructions for application to a wide
range of control
As an option, a process control instruction can be inserted in a loop that links process control
instructions.
Add the square root operation instruction (S.SQR) to perform the square root operation of an
input signal to provide an output signal as shown below.
Regulator
FE flow meter
Liquid
Diaphragm valve
FIC
[Example of adding square root operation instruction (S.SQR) to process control instructions]
Operation constant setting
Loop tag memory setting
R300R1000R240R140S.2PID R40
S.2PID instruction
Normal ON SD1506R200R100R0
S.SQR
R40R100EM0V
Process control instruction
(Square root operation
instruction) S.SQR
instruction
Process control instruction
(2-degree-of-freedom PID
control instruction)
Normal ON
Added as
option
(4) Automatic detection of various alarms
A system can be configured safely since various alarms are detected automatically in the
system.
1

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MELSEC-Q
1 OVERVIEW
(5) PID algorithm using a velocity type incomplete differential format
Partial differential has the following advantages over the complete differential format.
(a) The differential gain is 1/ and the limit value can be set.
(b) The output contains time amplitude, so the system actually responds to the operation edge
so the derivative operation makes the movement valid.
Manipulated
v
ariable
Time(t)
PID
Deviation
DV

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MELSEC-Q
1 OVERVIEW
1.2 PID Control Overview
PID control is applied to the process control of flow rate, speed, air volume, temperature, tension,
compounding or like.
In a configuration shown in Fig. 1.1, PID control maintains the object to be controlled at a preset
value.
Process control instructions
are used
SV
PV
PID
operation Automatic
MV
D/A
converter
module Controlled
system
Sensor
Set value
Manual
MV
MV
A/D
converter
module
Subdivided (micro-blocked) processings
of PID control
Fig. 1.1 Example of application to process control
PID control compares the value measured in the detection section (process value: PV) with the
preset value (set value: SV) and adjust the output value (manipulated value: MV) to eliminate the
difference between the process value and set value.
In PID control, proportional operation (P), integral operation (I) and derivative operation (D) are
combined to calculate the manipulated value that will make the process value equal to the set
value fast and precisely.
•If the difference between the process value and set value is large, the manipulated value is
increased to make it close to the set value fast.
•When the difference between the process value and set value has reduced, the manipulated
value is decreased to make it equal to the set value slowly and precisely.

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MELSEC-Q
1 OVERVIEW
1.3 Forward Operation and Reverse Operation
(1) Forward operation is the action that increases the manipulated value when the process value
increases more than the set value.
(2) Reverse operation is the action that increases the manipulated value when the process value
is decreasing more than the set value.
(3) Forward operation and reverse action make the manipulated value larger as the difference
between the set value and the process value becomes larger.
(4) An example of process control performed by forward and reverse operations is shown in Fig.
1.2.
Temperature Temperature
Time Time
Process value
Process value
Set value
Set value
Forward operation (for air conditioning) Reverse operation (for heating)
Fig. 1.2 Example of process control performed by forward and reverse operations

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MELSEC-Q
1 OVERVIEW
1.4 PID Control
This section explains "proportional operation", "integral operation" and "derivative operation"
performed for PID control using the process control instructions.
1.4.1 Proportional operation (P operation)
This section explains the control method using proportional operation.
(1) Proportional operation is the action that compares the deviation (difference between the set
value and the process value) to find the manipulated value.
(2) The change in relationship between deviation (DV) and manipulated value (MV) using
proportional operation is shown using the following numeric expression.
MV Kp • DV
Kp is called the proportional gain or proportional constant.
(3) The proportional operation when the deviation is a constant stepped response is shown in Fig.
1.3.
DV
Time
K DV
Deviation
Manipulated value
Time
P
Fig. 1.3 Proportional operation when deviation is constant
(4) The manipulated value fluctuates between 10 and 110%.
As Kp becomes larger the manipulated value corresponding to the deviation also becomes
larger making the compensation operation stronger.
(5) Offset occurs in proportional operation.

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MELSEC-Q
1 OVERVIEW
1.4.2 Integral operation (I operation)
This section explains the control method using integral operation.
(1) Integral operation is the operation that continuously changes the manipulated value to
eliminate deviation when there is deviation.
This operation can eliminate the offset that occurs during control performed by a proportional
operation.
(2) The time from when a deviation occurs until the manipulated value of the integral operation
reaches the manipulated value of the proportional operation in the integral operation is called
integral time (TI).
(a) Increasing the integral time decreases the effect of integration.
(It will take time to stabilize.)
(b) Decreasing the integral time increases the effect of integration.
However, since the integral operation will be stronger, hunting may become greater.
(3) The integral operation when the deviation is a constant value stepped response is shown in
Fig. 1.4.
K DV
DV
TI
Time
Manipulated value Deviation
Time
Proportional operation integral operation manipulated value
Integral operation manipulated value
Manipulated value in the proportional operation
P
Fig. 1.4 Integral operation when the deviation is a constant
(4) The integral operation is used as the PI operation that is combined with the proportional
operation or as the PID operation that is combined with the proportional operation and the
derivative operation.
Control cannot be carried out by merely performing the integral operation.

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MELSEC-Q
1 OVERVIEW
1.4.3 Derivative operation (D operation)
This section explains the control method using the derivative operation.
(1) The derivative operation is an operation that adds the proportional manipulated value to the
change speed to eliminate deviation when a deviation has occurred.
The derivative operation can prevent large changes in the object control from disturbances.
(2) Derivative time (TD) indicates the length of time from when a deviation occurred until the
manipulated value of a derivative operation reaches that of a proportional operation.
Increasing the derivative time makes the derivative operation stronger.
(3) The derivative operation when the deviation is a constant value stepped response is shown in
Fig. 1.5.
DV
Time
K DV
TDTime
Manipulated value for proportional operation
Manipulated value Deviation
P
Fig. 1.5 Derivative operation when the deviation is a constant
(4) The derivative operation can be used as PD operation in combination with a proportional
operation or as a PID operation in combination with the proportional operation and integral
operation.
Control cannot be carried out by merely performing the derivative operation.

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MELSEC-Q
1 OVERVIEW
1.4.4 PID operation
This section explains the control operation using combinations of proportional operation (P
operation), integral operation (I operation), and derivative operation (D operation).
(1) The PID operation controls the calculated manipulated value using (P I D) operation.
(2) The PID operation when the deviation is a constant value stepped response is shown in Fig.
1.6.
Deviation
Time
Manipulated value
Time
PID operation
I operation
P operation
D operation
PI
operation
Fig. 1.6 PID operation when deviation is constant

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MELSEC-Q
2 STRUCTURE AND COMBINATIONS OF PROCESS CONTROL
INSTRUCTIONS
2 STRUCTURE AND COMBINATIONS OF PROCESS
CONTROL INSTRUCTIONS
2.1 Instruction Configuration
The instructions that can be used by the process control instructions can be divided into the
"instruction part" and "device part".
The instruction part and device part are as follows.
• Instruction part..................This shows the functions for these instructions.
• Device part .......................This shows the data required for operations and the storage
destination of the stored operation results.
The device part is classified as the source device and destination device.
(1) Source (S)
The source stores the data used for operation.
(a) In the process control instruction, specify the head device that stores the source data.
(b) Data must have been stored in the specified device until the process control instruction is
executed.
(c) Changing the source data allows you to change the data used in that instruction.
(2) Destination (D)
Destination is where the data is stored after operation.
(a) Sets the device for which the data will be stored in the destination.
(b) Depending on the instruction used, data used for operation must also be stored in the
destination before start of the operation.
2