YOKOGAWA FA-M3 Vitesse Installation and operation manual

Technical
Information
TI 34M06Z42-01E
TI 34M06Z42-01E
2018.06 2nd Edition (YK)
Range-free Controller FA-M3
System Upgrade Guide
Yokogawa Electric Corporation
www.yokogawa.com/itc/

１. Introduction
1
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TI 34M06Z42-01E
2018.06-00
1. Introduction
The FA-M3 has been used in many systems since its debut in December 1992.
Early systems now require replacement of parts with service life for preventive
maintenance or system upgrade.
The operational economy of a system declines as it ages due to more frequent
aged deterioration related failures, obsolete functions and higher system
maintenance cost. Customers need to carry out appropriate upgrade to lower
cost and increase future corporate competitiveness.
This document focuses on the description of system upgrade to the latest product
models.
■NOTE
・Information in this document is current as of May 2018 and subject to
change without notice. Contact Yokogawa’s sales representative for the
latest information.
・For engineering support, contact Yokogawa’s sales representative:
Refer to Yokogawa’s website:
https://www.yokogawa.com/ioc/w-locations/ioc-w-locations-index-en.htm
・Proper nouns such as product and company names contained herein are
registered trademarks or trademarks of their respective owners.

１. Introduction
2
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TI 34M06Z42-01E
2018.06-00
1.1 Merits of System Upgrade
■Benefit from the latest technologies
●Technologies that were not well established when existing systems
were introduced can be put into practical use, and applied to system
control to greatly enhance efficiency.
■Benefit from improved basic performance
●Much faster controllers and the latest control equipment such as FA
servo and general-purpose inverters greatly improve system
productivity and economy.
■Benefit from networking
●Remote monitoring/control systems enable operation status of
devices to be monitored and maintained remotely over the Internet
and intranets. Adoption of an open network as represented by FL-
net allows flexible selection of equipment from different vendors.
Figure 1.1 Merits of system upgrade

２. System degradation and recommended replacement cycle
3
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TI 34M06Z42-01E
2018.06-00
2. System Degradation and
Recommended Replacement Cycle
2.1 Aged deterioration of system
■The failure rate of a system can be taken as the total failure
rates of its component parts. It has been shown empirically
that the deterioration of component parts is greatly affected by
installation environmental conditions as described below:
●Temperature: Failure rate doubles when temperature is 10°C higher
●Humidity: Corrosion of contacts accelerate when humidity exceeds
60%
●Corrosive gas: Causes corrosion of contacts
●Dust: Causes short circuit failures and corrosion
Figure 2.1. Aged deterioration of systems (Bathtub curve)

２. System degradation and recommended replacement cycle
4
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TI 34M06Z42-01E
2018.06-00
2.2 Recommended replacement cycle for
FA-M3
■Recommended replacement cycle: 10 years
However, modules that use parts with service life have the
following cycles.
●Modules that use aluminium electrolytic capacitors: 8 years
●Modules that use relays
Electrical life: 100 thousand cycles,
mechanical life: 20 million operations
●Modules that use photocouplers: 5 years
When used in high temperatures (about 45°C or higher)
IMPORTANT
・Recommended replacement cycle is a time period for preventive
maintenance of parts with service life, but is not a guarantee against random
failures.
・Recommended replacement cycle is a guide, and varies with operating
conditions.

２. System degradation and recommended replacement cycle
5
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TI 34M06Z42-01E
2018.06-00
2.3 Examples of failure of parts with
service life
■Aluminium electrolytic capacitor
●Generally, electrostatic capacitance drops, and electrolyte leakage
appears after 8 and 15 years respectively, and may cause power output
interruptions, changes in signal characteristics at power on/off and
circuit malfunction, etc.
■Relays
●Small relays have a mechanical life due to mechanical wear.
●Prolonged use may result in insulation degradation due to formation of
products of corrosion or conductive dust deposit, or poor contact due
to entry of dust and foreign substances at contact points or corrosive
film build-up on contact surfaces. Replacement at the recommended
replacement cycle is advisable.
■Photocoupler
●Generally, the light-emitting element of a photocoupler has an
expected life, and in some FA-M3 modules, wearout failures appear
after about 5 to 6 years depending on temperature and other
environment conditions.
Figure2.2 Electrolyte leakage Figure 2.3 Corrosion of contacts

２. System degradation and recommended replacement cycle
6
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TI 34M06Z42-01E
2018.06-00
2.4 Modules that use parts with service life
■Modules that use aluminium electrolytic capacitors
Recommended replacement cycle: 8 years
Table 2.1 Modules that use aluminium electrolytic capacitors
Category
Model name
Power supply module
F3PU□□-□N
F3PU□□-□S
CPU/power supply module for Value set
F3SP05-0P
F3SP08-□P
Analog input module
F3AD04-0N
F3AD04-0R
F3AD04-0V
F3AD08-1N
F3AD08-1V
F3AD08-4V
F3AD08-1R
Analog output module
F3DA02-0N
F3DA04-1N
F3DA08-5N
Temperature control/monitoring module
F3CT04-□N
F3CR04-□N
PID control module
F3CV04-1N
Positioning module
F3NC5□-0N
F3NC61-0N
■Modules that use relays
Electrical service life: 100 thousand times or more
Mechanical service life: 20 million times or more
Table 2.2Modules that use relays
Category
Model name
Power supply module
F3PU□□-□N
F3PU□□-□S
CPU/power supply module for Value set
F3SP05-0P
F3SP08-□P
Relay output module
F3YC08-0N
F3YC08-0C
F3YC16-0N
IMPORTANT
・The CPU module uses a large capacity lithium battery, which has continuous
backup capacity beyond its service life (10 years) but replacement (for each
module) at end of service life is recommended.

２. System degradation and recommended replacement cycle
7
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TI 34M06Z42-01E
2018.06-00
■Modules that use photocouplers (with recommended
replacement cycle below 10 years)
Recommended replacement cycle: 5 years (When used in
high temperature environment (about 45°C or higher))
Table 2.3Modules that use photocouplers
Category
Model name
FA link module
F3LP01-0N
FA link H module
F3LP02-0N
High-speed counter module
F3XP01-0H
F3XP02-0H
Analog input module
F3AD04-0N
F3AD04-0R
F3AD04-0V
F3AD08-1N
F3AD08-1V
F3AD08-4V
F3AD08-1R
Temperature control/PID module
F3CU04-0N
F3CU04-1N
Temperature monitoring module
F3CX04-0N

３. System upgrade procedure
8
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TI 34M06Z42-01E
2018.06-00
3. System Upgrade Procedure
3.1 Upgrading FA-M3
■Evolution of FA-M3
●The evolution of FA-M3 since its debut in 1992 has always considered
upward compatibility so an existing FA-M3 system can be easily
migrated to the latest FA-M3V.
■Upgrade procedure
●STEP 1: Select replacement module
Select a replacement module by referring to replacement product
table.
●STEP 2: Convert ladder programs
Ladder programs are upward compatible so existing programs
developed using earlier programming tools can be converted for new
programming environment.
●STEP 3: Other changes
・Adjust for higher processing speed
The faster processor in the latest sequence CPU module allows a much shorter
scan time. Timing adjustment might be necessary for scan-time dependent
processing.
・Modify ladder program after upgrading special module
Some special module models are software incompatible with replacement
products. Replacement guides are available for these.

３. System upgrade procedure
9
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TI 34M06Z42-01E
2018.06-00
3.2 Sequence CPU module evolution
Figure 3.1 Sequence CPU module evolution

３. System upgrade procedure
10
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TI 34M06Z42-01E
2018.06-00
3.3 Select replacement module (STEP1)
3.3.1 Replacement product table: Sequence CPU
module
Table 3.1Replacement products for discontinued sequence CPU modules
Item
Discontinued
product
Replacement
product
Compatible
Main changes
Programming
tool
Sequence
CPU
F3SP20-0N
F3SP22-0S
✓
High-speed/larger memory
WideField3
F3SP30-0N
F3SP71-4S
✓
High-speed/larger memory/built-in Ethernet
WideField3
F3SP21-0N
F3SP22-0S
✓
High-speed/larger memory
WideField3
F3SP25-2N
F3SP71-4S
✓
High-speed/larger memory/built-in Ethernet
WideField3
F3SP35-5N
F3SP76-7S
✓
High-speed/larger memory/built-in Ethernet
WideField3
F3SP28-3N
F3SP71-4S
✓
High-speed/larger memory/built-in Ethernet
WideField3
F3SP28-3S
F3SP71-4S
✓
High-speed/larger memory/built-in Ethernet
WideField3
F3SP38-6N
F3SP76-7S
✓
High-speed/larger memory/built-in Ethernet
WideField3
F3SP38-6S
F3SP76-7S
✓
High-speed/larger memory/built-in Ethernet
WideField3
F3SP53-4H
F3SP71-4S
✓
High-speed/larger memory/built-in Ethernet
WideField3
F3SP53-4S
F3SP71-4S
✓
High-speed/larger memory/built-in Ethernet
WideField3
F3SP58-6H
F3SP76-7S
✓
High-speed/larger memory/built-in Ethernet
WideField3
F3SP58-6S
F3SP76-7S
✓
High-speed/larger memory/built-in Ethernet
WideField3
F3SP59-7S
F3SP76-7S
✓
High-speed/larger memory/built-in Ethernet
WideField3
F3SP66-4S*1
F3SP71-4S
✓
High-speed/larger memory/no SIO port/USB1.1
→2.0
WideField3
F3SP67-6S*1
F3SP76-7S
✓
High-speed/larger memory/no SIO port/USB1.1
→2.0
WideField3
*1: Scheduled to be discontinued on 31 March 2019.
■Compatibility
●Ladder programs running on discontinued sequence CPU
modules can run on replacement CPU models by updating the
ladder programming tool.
■Precautions
●Programming tool
Latest programming tool WideField3 is required for using the latest F3SP7□-□S
CPU module. WideField3 is downward compatible with earlier CADM3, WideField
and WideField2.
●About F3SP7□-□N
F3SP7□-□N has been changed to F3SP7□-□S since January 2012 along with
functional upgrade. F3SP7□-□S should be used in future system upgrade.
●About multi-CPU configuration
F3SP7□-□□ cannot be used with AT compatible CPU modules and some old
sequence CPU module types in a multi-CPU configuration.
See reference "5.2 Restrictions on CPU module installation" for more details.

３. System upgrade procedure
11
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2018.06-00
3.3.2 Communication interfaces of sequence CPU
■Changes
●The replacement sequence CPU module has an Ethernet port.
●F3SP7□-□S has no RS-232C port. If a touch panel etc. was
connected via RS-232C, it is necessary to switch to Ethernet or
go via a PC link module.
●Dedicated ROM pack for program backup has been substituted by
a general-purpose SD card, which can also be used to store
device data.
Figure 3.2 Interface of sequence CPU
Table 3.2Interfaces of F3SP2□/3□/5□
Item
Media
Purpose
Communication
RS-232C
Programming and connection of display
Memory
Dedicated ROM pack
Program backup
Table 3.3Interfaces of F3SP7□
Item
Media
Purpose
Communication
Ethernet
Connection of PC and display
USB
Programming
Memory
SD (SDHC)
Data storage and program backup

３. System upgrade procedure
12
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3.3.3 Migrating from ROM packs
■When upgrading to F3SP7□-□S
●F3SP7□-□S uses general-purpose SD card for backing up ladder
programs but does not support ROM pack.
●Use SD card to back up ladder programs.
●The SD card supports various functions including backing up
ladder programs, saving device data and “PC-less” maintenance.
■When upgrading to F3SP22-0S
●F3SP22-0S supports ROM packs.
●F3SP22-0S supports the following ROM packs:
・RK33-0N RK73-0N
3.3.4 Replacement product table: Power supply/basic
I/O modules
Table 3.4Replacement products for power supply/basic I/O modules
Item
Discontinued product
Replacement product
Compatible
Changes
AC power
supply
F3PU01-0N
F3PU10-0S
✓
Supports AC100-240V/Consolidated
with F3PU10-0S
F3PU10-0N
F3PU10-0S
✓
Terminal screws M3.5→M4
F3PU20-0N
F3PU20-0S
✓
Terminal screws M3.5→M4
F3PU30-0N
F3PU30-0S
✓
Terminal screws M3.5→M4
DC power
supply
F3PU16-0N*1
F3PU16-0S
✓
Terminal screws M3.5→M4
F3PU26-0N*1
F3PU26-0S
✓
Terminal screws M3.5→M4
F3PU36-0N
F3PU36-0S
✓
Terminal screws M3.5→M4
DI
F3XD□□-□N
F3XD□□-□F
✓
Input response time selectable
DO
F3YD32-1A
F3YD32-1P
✓
Short-circuit protector added
F3YD32-1B
F3YD32-1R
✓
Short-circuit protector added
F3YD64-1A
F3YD64-1P
✓
Short-circuit protector added
F3YD64-1F
DI/O
F3WD□□-□N
F3WD□□-□P
✓
Input response time selectable
Short-circuit protector added
F3WD□□-□F
F3WD□□-□P
✓
*1 Scheduled to be discontinued on 31 March 2019

３. System upgrade procedure
13
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3.3.5 Replacement product table: Value/Valueー2
Table 3.5 Replacement products for discontinued Value sets
Item
Discontinued
product
Replacement
product
Compatible
Changes
Value set
F3SC21-1N
F3BU04-0N
F3PU10-0S
F3SP22-0S
F3WD64-3P
✓
①About Value/Value-2
・Sale of Value/Value-2 sets has ended.
・Individual modules need to be purchased
henceforth.
②Replacement precautions
・Requires Programming Tool WideField3.
・As the CPU module has higher processing
speed, verify system operation after
replacement.
・The power supply module uses M4 instead of
M3 terminal screws.
(applicable only when replacing F3SC21-1N)
F3SC22-1F
F3BU04-0N
F3PU10-0S
F3SP22-0S
F3WD32-3F
✓
F3SC23-1F
F3SC22-1A
F3BU04-0N
F3PU10-0S
F3SP22-0S
F3XD16-3F
F3YD14-5A
✓
F3SC23-1A
F3SC22-2F
F3BU04-0N
F3PU10-0S
F3SP22-0S
F3WD64-3P
✓
F3SC23-2P
F3SC23-2F
F3SC23-6P
F3BU04-0N
F3PU10-0S
F3SP22-0S
F3WD64-4P
✓
Service
items for
Value set
F3SP05-0P
F3PU10-0S
F3SP22-0S
✓
F3SP08-□P
3.3.6 Compatibility of basic I/O modules
■Hardware
●Replacement models use the same terminal block, connector, and
pin arrangement as discontinued products so are usable once
replaced.
●Latest output modules have built-in short-circuit protector.
■Configuration
●Replacement input module has wider range of input response
speed options.
・ Old product (model suffix N): Input response time: 16 ms, 1 ms
・ Latest product (model suffix F): input response time: Always, 62.5 μs,
250 μs, 1 ms, 16 ms
Note: 64-point module has no 16 ms option.

３. System upgrade procedure
14
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■Programs
●No ladder program change needed for upgrading to replacement
product.
Figure 3.3 Appearance of basic I/O modules
Figure 3.4 Reusing terminal block

３. System upgrade procedure
15
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3.3.7 Replacement product table: Special modules
Table 3.6 Replacement products for discontinued special modules
Item
Discontinued
product
Replacement
product
Compatible
Changes
Analog output
F3DA02-0N
F3DA04-6R
△
Terminal arrangement changed (common
terminals independent of output type)
Output type set by software (-10 to 10 V range by
default).
Output behavior at startup differs (no output until
setting is written)
High impedance.
F3DA04-1N
△
F3DA08-5N
F3DA08-5R
△
Output behavior at startup differs (no output until
setting is written)
Analog input
F3AD04-0V
F3AD04-5V
✓
Upward compatible. Wiring and terminal block
cannot be reused.
Different external dimensions (depth); terminal
block mounting position is in front.
F3AD04-0N
F3AD04-5R
✓
F3AD04-0R
✓
F3AD08-1V
F3AD08-5V
✓
Upward compatible. Wiring and terminal block
can be reused.
External dimensions (depth) differs; terminal
block mounting position is in front.
F3AD08-1N
F3AD08-5R
✓
F3AD08-1R
✓
F3AD08-4V
F3AD08-4W
✓
High-speed data
acquisition
F3HA08-0N
F3HA06-1R
△
No or minor modification of application programs
needed after replacement if module is used as a
high-speed AD conversion module, which refers
only to constantly updated data without using its
data acquisition function.
Application is incompatible and needs
modification if the data acquisition function or
acquisition-related filter function etc. is used.
F3HA12-1R
△
PID/Temperatur
e control
F3CV04-1N
F3CU04-1S
×
Software modification is needed.
F3CR04-0N
F3CU04-0S
×
Software modification is needed.
F3CR04-1N
F3CU04-1S
×
Software modification is needed.
F3CT04-0N
F3CU04-0S
×
Software modification is needed.
F3CT04-1N
F3CU04-1S
×
Software modification is needed.
Positioning
F3YP04-0N
F3YP24-0P
×
Software modification is needed.
F3YP08-0N
F3YP28-0P
×
Software modification is needed.
F3YP14-0N
F3YP24-0P
×
Software compatible. However, the number of
installable modules changed from 36 (288 axes)
to 16 (128 axes). Hardware incompatible. Need
to review external wiring such as changing from
5VDC to 24VDC.
F3YP18-0N
F3YP28-0P
×
Personal
computer link
F3LC11-2N
F3LC11-2F
△
Upward-compatible. Beware of position of rotary
switch.
Software modification is needed only if using
events.
F3LC11-1N
F3LC11-1F
△
Ladder
communication
F3RZ81-0N
F3RZ81-0F
×
Software modification is needed. For 1 channel.
F3RZ82-0F
×
Software modification is needed. For 2 channels.
F3RZ91-0N
F3RZ91-0F
×
Software modification is needed.
Ethernet
F3LE01-5T
F3LE01-1T
✓
Software compatible but has no AUI port and has
different look (e.g. connector location.)
F3LE01-0T
F3LE01-1T
✓
Software compatible but has different look (e.g.
connector location.)
F3LE11-0T
F3LE11-1T
✓
Software compatible but has different look (e.g.
connector location.)
F3LE12-0T
F3LE12-1T
✓
Software compatible but has no AUI port and has
different look (e.g. connector location.)
FL-net
F3LX01-0N
F3LX02-2N
✓
Software compatible. Beware of FL-net version.
F3LX01 (Ver.1) and F3LX02 (Ver.2) cannot be
mixed.
F3LX02-1N
F3LX02-2N
✓
Software compatible but has no AUI port and has
different look (e.g. connector location.)

３. System upgrade procedure
16
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Item
Discontinued
product
Replacement
product
Compatible
Changes
NX autonomous
distributed
F3NX01-0N
F3NX01-2N
✓
Software compatible but has no AUI port and has
different look (e.g. connector location.)
F3NX01-1N
F3NX01-2N
✓
Software compatible but has no AUI port and has
different look (e.g. connector location.)
FA link H
F3LP01-0N
F3LP02-0N*2
（F3LP□□-□
N*3）
✓
(Software compatible but hardware incompatible.
New and old products cannot be mixed)
F3LP02-0N*2
（F3LP□□-□
N*3）
✓
(Software compatible but hardware incompatible.
New and old products cannot be mixed)
Fiber-optic FA
link H
F3LP12-0N
*2
None
-
Replace with combination of FL-net and optical
cable converter.
μbus
F3LU01-0N
None
-
Need to replace with YHLS etc.
Modem
F3LM01-1N
F3LC11-1F
-
Replace with combination of F3LC11-1F and
external analog modem.
*1 F3DA04-6R/DCR with default current (4 to 20 mA) output type is available for customers using current output. Contact
Yokogawa's sales representative for details.
*2 Scheduled to be discontinued on 31 March 2019
*3 New product scheduled for sale in December 2018.
3.3.8 Application compatibility of special modules
■As replacement models become more powerful, application
modification is needed for some special modules.
■Even with application compatibility, processing timing may
change due to faster processing speed so you should always
verify system operation after module upgrade.

３. System upgrade procedure
17
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3.4 Convert ladder programs (STEP2)
3.4.1 Ladder programming tools table
■Sequence CPU modules versus programming tools
●WideField3 is required for using the latest F3SP7□/F3SP22 CPU
modules.
Table 3.7 Sequence CPU modules versus programming tools
Release
year
1995
1999
2002
2011
CPU model
Programming tool
CADM3
WideField
WideField2
WideField3
Availability for sale
SF511
SF610
SF620
SF630
1993
F3SP20-0N
Discontinued
✓
1993
F3SP30-0N
Discontinued
✓
1995
F3SP21-0N
Discontinued
✓
✓
✓
✓
1995
F3SP25-2N
Discontinued
✓
✓
✓
✓
1995
F3SP35-5N
Discontinued
✓
✓
✓
✓
1999
F3SP28-3N
Discontinued
✓
✓
✓
1999
F3SP38-6N
Discontinued
✓
✓
✓
1999
F3SP53-4H
Discontinued
✓
✓
✓
1999
F3SP58-6H
Discontinued
✓
✓
✓
2002
F3SP28-3S
Discontinued
✓
✓
2002
F3SP38-6S
Discontinued
✓
✓
2002
F3SP53-4S
Discontinued
✓
✓
2002
F3SP58-6S
Discontinued
✓
✓
2002
F3SP59-7S
Discontinued
✓
✓
2006
F3SP66-4S*1
To be
discontinued
✓
✓
2006
F3SP67-6S*1
To be
discontinued
✓
✓
2011
F3SP22-0S
Available
✓
2012
F3SP71-4S
Available
✓
2012
F3SP76-7S
Available
✓
*1 Scheduled to be discontinued on 31st March 2019.

３. System upgrade procedure
18
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3.4.2 Ladder program conversion and compatibility
■WideField3’s conversion feature
●CADM3, WideField and WideField2 projects can be converted to
WideField3 format by loading them into WideField3.
Figure 3.5 Conversion illustration
■Upward and downward compatibility
●A project converted to WideField3 can also be saved in the old
format.
Figure 3.6 Upward and downward compatibility

３. System upgrade procedure
19
All Rights Reserved. Copyright © 2018, Yokogawa Electric Corporation
TI 34M06Z42-01E
2018.06-00
3.4.3 Converting ladder programs (CADM3)
■Converting from CADM3 to WideField3
●CADM3 will not run under the latest Windows so you need to port
files including the executable from the PC running CADM3 to the
PC running WideField3.
●Files to be ported
Executable program file: extension ＝.PRG
Block files: extensions ＝.BLK .OBT .CMT
Macro blocks: extensions ＝ .MBL .MOB .MCM
Table 3.8 Programming tool versus supported OS
OS
CADM3
WdeField
WideField2
WideFiled3
MS-DOS
✓
Windows95
✓
✓
Windows98
✓
✓
WindowsNT
✓
✓
Windows2000
✓
WindowsME
✓
WindowsXP
✓
WindowsVista
✓
Windows7
✓
Windows8,8.1
✓
Windows10
✓
IMPORTANT
・In CADM3, project (executable program) and blocks are stored in a folder
(directory) with a name defined by a user using CAM3’s initial design menu.
Normally, programs to be ported are stored near individually defined
directories. (In CADM 3, folder name and project name do not match.)