Mitsubishi MELSEC F2-60MR User manual

11
I
M'TSuB'SH' Programmable Controller MELSEC F2 SERIES
INSTRUCTION MANUAL
I
F2-60MR
0 This manual provides technical information and guidance on the installation and
rise of the Mitsubishi Fz series ProgrammableController and its extension unit.
e Users should ensure that the detail of this manual is studied and understood
before attempting
to install or use the units.
0 Information concerning the programming of the system, using the programmer
unit,
is covered in a separate manual.
MWSUBISHI ELECTRIC CORPORATION

TABLE QF CONTENTS
1. INTRODUCTION
1-1 Descriptionsof
F2 series PC .....................................
1-2 Basic models of base unit & extension unit
1-3 Extensionunit selection .......................................
1
1
2
...........................
1-4 Peripherals ...................................... l........ 2
2-1 Powersupply.. ............................................ 3
2-2 Grounding.. ....................................
.:. .......
2-3 RUN/STOP modeterminals
1 5
2. PRELIMINARY WIRINGS
5
2-4 RUNoutput terminals ......................................... 5
2-5 DC24V terminals 5
3-1 Example of connections. 6
3-2 Input terminals.. 6
........................... ........
.................................. ........
3. INPUT HANDLING
.......................................
............................................
......................................
3-3 Inputcircuit specifications 7
3-4 Cautions. 7
3-5 AC inputhandlings ..........................................
9
4-1 Relay outputmodels ..........................................
4-3 Transistor outputmodels {Sinkoutput)
11
4-4 Transistor outputmodels (Sourceoutput)
12
4-5 Output circuit specifications 13
5-1 Installation *! - * - * - - - 15
5-2 Connections of inputcircuit 16
5-3 Indicationsand
DIP switch settings ................................ 16
.................................................
8
4. OUTPUT HANDLING
4-2 Triac
(SSR) output models .I. ........ 10
...........................
.............................
.................
-t* - * - - * - - *
.....................................
5. F2-40AC (HIGH SPEED COUNTER INTERFACE) HANDLfNG
.....................................
.....................................
6. F2-.(IOAW/AP (PC LINK INTERFACE) HANDLINGS
6-1 F2-40AW Instidlation .......................................... 17
6-3 Indicationsand DIPswitch settings
18
6-4 Signal transmission 18
6-2 F2-40APInstallation ..................................... .... 17
..................... .........
..........................................
7. LNSTALLATION AND ENVIRONMENT
....... .....................................
7-1 Installation
i.. 20
7-2 Extensioncable
20
7-3 Environment
20
7-4 Electricalnoise interference
20
7-6 Peripheralinstallation 21
8-1 Preliminarychecks 22 -
8-2 Diagnosis 22
8-3 Maintenance ................................................ 23
......... ..................................
........ ..................................
-.;.
7-5 Wirings.. -;.
....................................
........ .....................................
21
.........................................
8. DIAGNOSISAND MAfNTENANCE
..........................................
................................................
Appendix
...........................................
1. SPEC IF ICATIONS 24
2. OUTLINES AND DIMENSIONS.. 25
...............................

I, I
1-1
1-2
DESCRlPTlONS OF F2 SERtES PC
The Mitsubishi F2 series of programmabte controllersand auxiliary equipmentsare higher version
models
to the F series andare ideal for small industrialprocesscontrot requirementsand machines.
The
1/0 capacity is 120pointsmax. per unit, but 240 11'0s can be covered by tinkageoperation.
A separate ranges the
G series and K series are availablefor larger and morecomplex application
requirements.
BASfC MODELS OF BASE UNIT & EXTENSION UNfT
Nomenclatures of Base & Extension Unit
Model Fz - a D .. D Ct
111 It
II
ir
Expl. F2 - 40 M R
- E S
I It tI
indicatesthe number of inputs/outputs 40or 60
indicatestype of the unit
indicates type
of output
R: Relay, S: SSR, T: Transistor
specifies power supply voltage rating
M: Base Unit or E: Extension Unit
N/A .......
U& u L......
E . . . . . , ,
D . . . . . . .
indicatestype
N/A _......
s
AI .......
A2 .......
ss
. . . . . . .
. . .. . ..
100/1 IOVAC 200/220VAC
1 10/1 ZOVAC 220/240VAC
110/220VAC, 220/240VAC
24VDC
3f input/output connections
24VDC sink input and sink output
24VDCsource input and sink output
100/120VAC source input and sink output
220/240VAC source input and sink
output
24VDCsource input and source output
-1-

I
F2-20H
G P-80 FZ
F-ROM-1
F -20P-CAB
F2-40AC
F2-40AW
F2-40AP
13 EXTENSION UNIT SELECTION
Program Loader
Graphicprogrammer
EP-ROMcassette
Remotecable
Adaptor (Highspeed counter input interface)
Adaptor (Wire
I ink operation interface)
Adaptor (Opticalfiber link operation interface)
I
The F2-40M has wo extension ports and F2-60Mhas three extension ports where extension units
are connected. According tothe requirements
of t/O numbersand other additional functions, select
the unitswithin following applicablemodels;
Output: 16
Input: 4 Output: 6
).
" 12, " 8
" 24, *' 16
*' 24, " 16
Output: 24 r' 36, " 24
4 point Analog timer unit
Positioning counter module
14 PERIPHERALS
According to different function requirementsfar the peripheral equipments, wide range of periph-
erats are provided
as follows;
1 F-2OP-E I Handy programmer I
F2 -20P-E (Highfunction)
F-20MW
1 ROM writer
t
?I ?I
1 GP-80ROW I " " (Highfunction) I
Above peripherals can afso be used for the F series PC except F2-40AC, F2-40AWand F24OAP.
.-2-

I" I
Example of sink DC input model (F2-40/6000, F2-40/60cfU-U)
RUN -
(-U Type)
Example of source DC inputmodel (F2-40/60CICl-ES)
R IJN
1 ?0/120VAC or
I1
2-1 POWER SUPPLY
Power supply voltage ...............
AC 110/120V
type models)
ACI10/120V+IO% or AC220/240V +IO% 50/60Hz (-UL type
model)
Power consumption
.................
less than 24VA (F2-40), less than 40VA (F2-60)
DC
24V output capacity .......... 0.1A (F2-40DCinput model), 0.2A (F2-60DCinput model)
or AC 220/240V zigz 50/60Hz (-4, -ES
j (Externalpower source) (Exctudethe power to non-voltagecontacts)
I
-3-

IF-
Example of sink DC input model(F2-40/60C1lJ-D)
RUN
Earth -
POWER
24VDC
/L f-b
7 I I
r'
I A m m
Ah
TI I ri
7
* Ensurethat the input [=I terminal is connected tothe power @ terminal as
illustratedabove.
Example of source DC input model (F2-40/60DCI-DS)
* Ensurethat the input 1- terminal is connectedtothe power, 0 terminal as iltustrated
above.
POWER SUPPLY
Power supply voltage .. . . . .. 24VDCk8V
-4-

*-
2-2
2-3
2-4
2-5
(1) Connect a power supply cableof the correct ratingtothe base unit and extensionunit (ifused)
as illustrated. Supply voltages should be as specified. I ommended to provide,power
supply switchwhich can be usedwhen the ROM cassette
i
(2) The power consumption of the base unit is less than 25VA to F2-40 and 40VA to j F2-60
however, this does not includethe power consumptionof any external load.
(3) The power must be switchedoff when the ROM
cassette is loadedon the base unit or unloaded
from the unit.
(4) The, power supply
to the extension (ifused)shall be connectedto same ON/OFF switch,forthe
base unit.
.. -
GROUNDING
(1) The unit must be grounded as illustrated.The extension unit (if used) also be groundedwith
same lineof base unit.
(2) Resistanceshould be less than 100G.
(3) Groundingmust not be sharedwith any highpower equipmentsuch as a motor system.
RUN/STOP MODE TERMINALS
These terminals should be connected to key switches or other suitable control devices (push
button) as illustrated.
The RUN mode
is used when the programmabiecontroller is running a program (controlling a
system).
When the STOP mode
is used (or there is a power failure of more than 20m/sec.), aflioutputs
are turned off and timers, plus the 128 of
192 auxiliary relaysare reset. However, ail counters
and
64 of the auxiliary relays, state relaysand some special auxiliary relaysare maintainedby
batterysupport.
When the 'STOP' switch
is on, all outputs will be 'OFF'. However it is recommended that
externalfacilitiesbe providedin
case of emergencies to support and back up this facility.
incase of
AC input models, see section 3-5.
RUN OUTPUT TERMINALS L-dor U
(1 ) A relay contact is provided between these two terminals inside. The contact is switchedon at
normal run mode, but is switched off if CPU error might be causedfrom electrical nqise inter-
ference,
etc It is switchedoff inSTOP mode.
(2) This facifity is usedto make an emergency stopcircuit or warningcircuit.
(3) Output load of the relay is less than 35VA. For loadsover the rated limit, operation should be
performedthrough an extra relay.
DC24V TERMINALS
Incase of the sink input models, inputdevices of non-voltagecontactsare poweredfrom input
terminals and the
24+ terminals provide DC24V power for input sensor devices such as prox-
imity switchesor photo sensors.
In case
of the source input models, non-voltagecontact devices are powered from the 24V
terminals and the 24V terminals have extra power capacity for the input sensor devices as
specified.
Ifthe extensionunit
is used, connect the DC24V terminals between the base unitand extension
unit. The
COM terminals are also connectedinthe same manner.
Any externalpower must not be suppliedto these terminafs.
!
-5-

'/I.
,,, -/I--
,$ ".,
3-1 EXAMPLE OF CONNECTIONS
(1) Sink input modefs (F2-40/60170, F2-40/6OOO-U, F2-40/6OUO-UL)
Proximity
K
24+
Push button Limit Rotary Timer
switches switches switch contact
(2) Source input modefs ~FZ-~O/~OCICI-ES)
Proximity Push button Limit
I
switches switches
6mA 505 506
24+ ov
Rotary Timer
switch contact
3-2 lNPU1 TERMINALS
-6-

3-3 INPUTCIRCUIT SPECIFICATIONS
Operation
current
__ ~
1 OC24V Input DC24V Input
(Sink input)
DC4mA Min.
OFF-'ON DC4mA Min.
I I
Response
time
lnpuf
Input circuit
OFF-'ON Approx.
l0m.sec
Approx. 10m.sec
ON-+OFF Approx. 5m.sec Approx. 5rnsec
DC24V
=k 4V
DC24V 54V
(Self-supply) (Self-supply)
Rated inputvoltage
I I
I I I
Insulation Photocoupler insulation
lnout
AC2mA Max. AC2mA Max.
Approx. 15m sec
Approx.
8m sec
Approx.
t5m sec
Approx.
8m sec
I
Indication 1 LEDturnsONwhen input is activated.
3-4 CAUTlONS
(I) Connect input control devices, e.g. limit switches, push butto&, to the input terminations as
specified.
(2) Incase of sink input models, non-voltagecontactdevices are poweredfrom the inputterminals
and the 24V terminal points can be used to power external transistors such
as proximity
switches.
The capacity of 24V DC source is rated by 0.1 Amp (F2-40) and 0.2 Amp (FZ-60) from 24V
terminalinadditionto each 7mAfrom
all inputterminals.
(3) In case of source input modefs, non-voltage contact devices are powered from the 24V termi-
nals and the current rating
at each input terminal is 24VDC, 6mA. The control devices should
be specifiedaccordingly.
The 24V terminal points can also be used to power externaf transistors such
as proximity
switches.
Totaf
of 0.1 Amp (F2-40)and 0.2 Amp (F2-60) currentby two 24V terminals can be usedfor
such transistors inadditionto each
6mA suppty to all inputterminals.
Iffurther more power
is requested, use an externaf power source of 16 to 36V DC.
The OV terminals are used for negativesof 24V DC source.
(4) If transistor circuits, such as proximity switches, are connectedto input terminals and have a
parallel or series resistance, their parallelshould be more than 10OKL-l andtheir series resistance
less than 1 KO2.
(5) Three common terminals are connected internally and are common. However, thte base and
extension unit commons are not linked unless connected together externalfy
as detailed in
other section.
The commonterminal
is also used for a negative of 24V DC source.
(6) For the sake of convenience andappearance andto avoiddamage of failure, input wires should
be boundor cabledtogether.
It: is recommended that input wires are not longer than 20 metersfor the general use, However,
the tength can be longer but depends uponthe conditionsof the noise environmentand voltage
drop.
-7-

3-5 AC INPUT HANDLINGS (F2-40/60OO-C1A1, A2)
When no contacr input devises such as proximity switches or photo sensors are connected to
input terminals, be aware that the leakage current may activate the input signal incorrectly.
Where the leakage current
is more than 2mA, it may prove necessary to provide additional
bleeder resister
or CR circuit (ex. 0.5yF + IOOSt), otherwise use input devices with tow leakage
current
less than 2mA.
Run stop
switch switch Limit switch
1 IO/
I20V
- (Example: F2-40MR-UAi 1

4-1
RELAY OUTPUT MODELS (FZ-40/6OO R, -0U)
4 points 4 points
cornmo n common
4 points
common
4 points
common
\-\/u-
4 points
4 points 4 points
4 points
4 points 4 points
common common common
common
common common
Connect external load devices e.g. contactors, pilot lamps, solenoid (electromagnetic)valves, etc.,
to outputterminations of the base unit and extension unit (if used).
As shown in the above figure, four common terminals are provided for the outputterminations.
As these commons are not linked and cover each four output terminals in their block, different
types
of power can be used as shown in the above exampte as far as the output terminals in a
block share onetype of power.
t
-9-

/ -''I*\
0 Normal open relay contacts are connected internally to the output terminals on the base and
extension units, The ratings
of the contacts are 2A at 24V DC, 110/120V AC, 220/240V AC.
These ratings apply for resistive loads (COS (6 = 1 .O).
The durability data of output relay is stated in other section (4-5).
0 Each internai contact is protected by a residual current circuit. When the contact is closed, its
current leakagewill normally be less than 1 .lmA at 220V AC or 0.55mA at 21OV AC.
However, it is possible that this might have some effect on external loads.
Where the external current demand
is very low, it may prove necessary to provide additional
parallel resistance because
of the influence of leakage (see section 4-5).
e When using the controller in a direct current circuit, it is recommende'd to connecta free whee!
diode in paratlel
to the inductive load.
@
4-2 TRIAC (SSR) OUTPUT MODELES (F2-40/60cIS, -DU)
1'09" 1 44 0 I 44 1 1 44 2 I 443 r:2 I 444 f 445 f 446 I 447 1
54 0 1 54 t 1 54 2 I 543 IC,?? I 54415451546 1 547 I
2
4 points 4 points
common common
4 points
common
4 points
common
4 points
4 points
4 points 4 points
4 points 4 points
common common common common common common
- 10-

I/ ,
I
Connect externalloaddevicese.g. contactors, pilot lamps, sotenoid (electromagnetic) valves, etc.,
tooutputterminationsof the base unit and extension unit (if used).
As shown in the above figure, common terminals are provided for the output terminations.
As these commons are not linkedand cover each four output terminals intheir block, different
types of power can be used
as shown in the above example as far as the output terminals in a
block share one type of power.
The load limitation of the triac
(SSR) outputs is 1A for each individualoutput, but the total
collective output load should no exceed
8A across all 16 outputs at AC 110/120V or AC 220/
24OV.
For inductance loads, the ratedcoil of magnetic contactors sl-tould be within 50VA at AC 110/
be required. For lamp loads above IOOW, an externalrelay will atso be required.
Each triac
(SSR) inside the unit will withstand moderate surge currents, and is protqcted bv a
residual current circuit. With the triac 'off' current leakage is less than 1.2mA at AC 120V or
2.2mA
at AC 220V. However, it is possiblethat this might have some effect on externalloads.
It is not possible tooperatetriac output card on DC toads.
I
12OV or 100VA at AC 220/240V. Ifthe coil toad is over these limits, then an externa1)relay will
i
?
4-3 TRANSfSTOR OUTPUT MODELS (F2-40/60CIT, -17)
SINK OUTPUT TYPE
1 DC24V 0 14301431 /4321433143414351436f437[53015311532[5331534i 535[536[5371 DC24V 0 I
d
2A t
P
b
4
DC24VO 31 33 35 37 431 433 435 437 531 533 535 537 DC24VO
40 42 44 46 440 442 444 446 540 542 544 546
DC24VO
41 43 45 47 441 443 445 447 541 543 545 547 DC24V @

0 Connect externalloaddevices e.g. contactors, pilot lamps, solenoid (electromagnetic) valves, etc.,
0 The load limitation of the transistor outputs is 1A for each individualouiput, but the collective
output toadshould notexceed
2A per 4 points at DC 24V.
8 Due tosurge current limitations lamp loadsshould be within 3W.
0 When other loadare connectedto a outputterminationinadditionto lamp load, the totaf collec-
tive output load should be as specifiedwith referenceto followingtable.
tooutput terminations
of the base unitand extensionunit.
i
\
2w 6W
1w I 16W
I I
0 24W
I
0 The external DC power supply should be DC 24V +15%/-30%.
0 2A rated back-upfuses or protectorsare recommendedper each four outputs 'to preventdamage
to the circuit boards
of the PC inthe event of a short circuit fault inone of theexternalcircuits.
4-4 TRANSISTOR OUTPUT MODELS (F2-40/600T-ESS) SOURCE OUTPUT TYPE
1 130 I 32 I34136 1 14301432143414361 15301532153415361 I 1 I
DC24VO 41 43 45 47 441 443 445 447 541 543 545 547 DC24VQ
- 12 -

11
Connect externalload devicese.g. contactors, pilotlamps, solenoid (electromagnetic)
tooutput terminationsof the base unitandextension unit (if used).
The
load limitation of the transistor outputs is 1A for each individualoutput, but
output loadshould not exceed
2A per 4 points at DC 24V.
Due tosurge current limitationslamp loadsshould be within 3W.
When other loadare connected to a output termination in additionto lamp load, thetotal collec-
tive output loadshould be as specifiedwith referencetofollowingtable.
2w 6W
1w 16W
0 24W
i
The external DC power supply should be DC 24V +I 5%/-30%.
2A rated back-upfuses or protectorsare recommendedper each four outputsto prevent damage
to the circuit boards of the
PC inthe event of a short circuit fault inone of the external,circuits.
4-5 OUTPUT CIRCUIT SPECIFICATIONS
Relay Output Triac Output Transistor Output
(Sourceoutput)
Transistor Output
(Sink output)
~~
Output circuit
+?O%
24vDc-30%
Less than 250VAC
I30VDC
2AIpoint
Detailed below
+lo%
24VDC-30F
tA/point but 2A
per
4 points total
24W (24VDC)
3W (Detailedin
Section4-4)
SA11 Oms
External powersource
Ratedoutput current
(Resistanceload)
Lampload
Rush current
Leakagecurrent
Min. Load
(Inductive load)
80-240VAC
tA1point but 2A
per
4 points toral
50VA
(1 loll 20VAC)
1 OOVA (220/240VAC)
IA/point but2A
per
4 points total
24W (24VDC)
3W (Detailedin
Section 4-3)
tOOW lOOW
1OAICycle
1.lmAIllOVAC
2.2mA1220VAC
1OAICycle
0.55mA111OVAC
l.lmAl220VAC
BAllOms
-
0.2VAlllOAC
0.8VAl220VAC 0.4VAIlTOVA
1.6VAl220VAC
-
I
Lessthan Irn.sec
Less than 1m.sec
Photocoupler
Approx. 5m.sec Less than 1m.sec
Response
time
Circuit insulation
Indications
Less than 1m.sec
Approx l0m.sec 1Om.szc Max. Lessthan 1msec
!
Relay insulation Photo-triac Photo-coupler
LED(Whentriac is
activated) LED(Whenphoto-
coupler is activated) LED (Whenphoto-
coupler isactivated)
LED (Whenrelay
coil
is activated)
-13-

The basic unit and extension unit have the output power ratings indicated in the above table. For
loads over the rated maximum limits shown, operation should be perforhed through
an extra
relay, capable of handling the load. Loads under the minimum limits shown
will need an additional
surge absorber circuit (approx.
O.1pF + 1OOSt) to prevent incorrect operation due to leakagecurrents
ftowing
in the output circuits.
Less than
35VA
Less than 80VA
Less than 120VA
on
I
Back-up fuses or circuit protectors are recommended on output circuits to prevent damage to the
circuit boards of the
PC in the event of a short circuit fault in an external output circuit.
Inductive toad of Relay Output
Appticabte toads to the output relays are subject to the frequency of operations. According to our
life test data, followingsare given for
a reference of the relay durability level;
UP to 3,000,000
UP to 1,000,000
up to 200,000
I

--
5-1 I NSTAL LATI ON
'ER
1) Connect a connector of the F2-4OACto
2) Fit the hooks in the installation holes of
3) Slide the plastic cover upward,toremove
4) Connect the input wires tothe terminals
the
PC.
the PC.
thecover.
andadjust the
DIP switch.
- 15-
I

3 5-2 CONNECTIONS OF INPUT CIRCUIT
Example of proximity switch
lt---ll---
Proximity switch
Pulse: 2KMz Max
(ON: 0.25ms, OFF: 0.25ms)
5-3 INDICATIONSAND DIP-SWITCHSETTINGS
Terminals
LED indications:
1 ....... Mode selection tM470)
2
....... Up/downselection (M471)
3 ....... Start (M472)
4 ....... inputsignal
DIPswitch
setthgs:
SWI ....... Switch ON only when 5VDC is used for inputdevice.
SW2 ....... Switch ON only when 12VDC is used for inputdevice.
SW3 ....... Switch ON onlywhen 24VDC is used for inputdevice.
SW4 ....... Switch ON only when inputfilter is required.
-16-
"_ .......... .....
... ..... .............
. ..
.. .... . 1- L.- " '-1
yl_ ..,... .-,-- ,~-..," I
~ "".,~,,, ~, ;,,: ~,,,~,""- -,l._ll.ll II .-.I" -.,.,.-" I

c:
6-1 FZ-4OAW (WIRE LINK) INSTALLATION
Fz-40A W F2-40A W
Attach the unit to the PC in thesame manner as the F2-40AC (Section5-1).
Connect two
units with a twist-pair cable as illustrated (SA to SA, SB to SB), and both ends of
sealing twist are connected to the earth terminals of the PCs.
The cable length shall be less than 10 meters (approx. 35 feet) and keep away from high voltage
suppty cables
or other such electricalapparatus to avoid electrical noise interference.
6-2 FZQOAP (OPTICAL FIBER LINK) INSTALLATION
Optical
/
Optical
connectors
Attachthe unit to the PC in the same manner as the F2-40AC (Section 5-1 ).
Connect two units with optical plastic fiber cablesas illustrated (R to T, T to R).
Thecable length shall be less than 50 meters (approx. 160 feet).
Theopticalfiber cables and opticaf connectorsare
not included in the attachment. The material
specifications and
supply shall be inquired to Mitsubishi agent.
-17-

_-_ -. .,_ .r.'.., .
.... .......... .... .r:i.r..-a.-..
6-3 INDICATIONS AND DIP-SWITCH SETTINGS
6-4
(Expt. F2-40AW)
LEDindicatigns:
1 ....... Power supply
2 ....... Linkage RUN
3 ....... Signal transmission
4 ....... Transmission error
DIP switchsettings:
SW1 ....... Switch OFF atany time.
SW2 ....... Switch ON atany time.
SW3 ....... Since two PC unitsmustbeidentified for thesignal handlings mentioned in the next
section
64, the SW3 makes identifications of both PCs as follows:
ON ....... Side A PC(Master)
OFF ..... Side B PC (Slave)
SW4 ....... Switch ON to transmit 32 points of signals or switch OFF to transmit 16 points of
signals.
SIGNAL TRANSMSSION
For the linkage operations of two PCs, certain auxiliary retays are shared with both PCs and the
signal transmissions are as follows:
(I ) 32 PointsTransmission
Side B (Slave) PC
Side A (Master) PC
I Receiving
Side B PC can activatetheauxiliary relays M100-Ml37 subjectively and Side A PC receives the
data
to share with thecontacts in the program. On other handauxijiary relays M140-MI77 are
activated
by Side A PC andthe data is shared by Side B PC with thecontacts.
(Auxiliary reiay
M100-M137 cannot be activated by Side A PC and M140--177 cannot be
activated
by Side B PC.)