Duration: 5 days
Prerequisites: Delegates should be familiar with using a PC/laptop with Microsoft Windows
applications & understand the very basics of PLCs.
Aims: The course is aimed at the beginner with Mitsubishi PLCs & software & will cover First-line Maintenance skills needed to be able to support simple applications. The last 2 days focus on use of the full diagnostic toolkit to effectively troubleshoot Mitsubishi hardware problems & machine or process faults. The course is entirely practical & consists of troubleshooting a range of fault scenarios to establish a logical approach to fault-finding & to reinforce the use of standard tools & test procedures.
Content:
MITSUBISHI FX, Q & A SERIES PLC FIRST-LINE MAINTENANCE
FX, Q & A Hardware Familiarisation. Local & Remote
• Identification of Main FX, An & Q Hardware elements
• Identification of communications hardware inc. RS422, RS232, USB &
Ethernet
• An overview of common Fieldbus principles e.g. Profibus & CCLink inc. awareness of extra software hardware needed for configuration of these networks
• Field wiring principles for DC Signals. Pos or Neg switching & how to test
Familiarisation of Mitsubishi Addressing
• Understanding Q & A series Geographical addressing for I/O Hardware
• Understanding FX Sequential addressing for I/O Hardware
• Overview of Special Function Block Addressing e.g. Analogue I/O
Overall System Familiarisation & Diagnostics
• Understanding where everything is connected & why
• Understand the position of the Mitsubishi PLCs with relation to ETerminals
(HMIs), SCADA, Fieldbus networks, GX Developer / GX IEC Developer & other utilities
• The principles of using E-Terminals (HMIs) & other visualisation products for PLC & Process diagnostics
• Interpretation of main system indicators for visual fault diagnostics
• Considerations for changing faulty hardware in an FX, An, & Q series Mitsubishi system
Software Familiarisation Stage 1
• Understanding of the various software products available from Mitsubishi inc. GX Developer & GX IEC Developer
• Using the right tool for the right job GX Developer or GX IEC Developer?
Getting Started
• Getting to know the GX Developer / GX IEC Developer working environment
o An overview on how the menu & toolbar features operate
o Understanding the screen layout
o Concentrating on what’s important & not on what’s not
o Changing the mode of GX Developer
− Read vs. Write vs. Monitor Write
Basic Communications Connections & Communications Media
• Getting connected to a Mitsubishi Controller
o Understanding the Connections & Media
o Understanding the when & why of Software related settings
• Troubleshooting common communication faults
Software Familiarisation Stage 2
• Reading From & Writing to the PLC
• Verifying Online & Offline processor images
• Searching & cross-references
User app. Software. Ladder Logic Stage 1
• The ladder Logic concept relating to Mitsubishi PLCs
• Overview of other PLC programming languages e.g. STL (Stepladder)
Introduction to I/O & Memory devices
• Relating Field I/O to PLC code
• Understand the use & importance of internal I/O
o Internal Relays (M, L) & Special Relays (M, SR)
o Timer / Counter Memory allocation
Understanding the Connection to PLC Hardware
• Correct interpretation of screen highlights for bit type instructions
Changing PLC Modes of operation.
• Understand the implications of PLC mode changes
• Remote operations. RUN / STOP using GX Developer
• Local operations. RUN / STOP using the Hardware
Transferring User Applications
• Understand the implications of overwriting PLC Memory
• Clearing the PLC Memory
o ALL Clear
o Device Clear
• Understanding partial transfers of: -
o Program
o Data / Device Tables
o Parameters
User App. Software Stage 2
• Understand the implementation of Mitsubishi Timers
• Changing Timer Presets during runtime
Familiarisation of Software monitoring options & Forcing / data manipulation
• Exploration of GX Developer Monitoring options
o Monitor
o Monitor Write
o Batch monitor
o Device Monitor
o Ladder Monitor
• Understanding the implications of Forcing
• Using the GX Developer Force function & knowing its limitations
File Management & Backups
• Introduction to File management good practice
• The principles of maintaining program backups
User Application Documentation maintenance
• The importance of adding & maintaining project documentation to aid diagnostics
• Using documentation & search features to make finding code sections quick
MITSUBISHI FX, Q & A SERIES PLC TROUBLESHOOTING
Logical Approach to Fault-finding
• Understand what should be happening
• Understand what is/is not happening
• Understand the reasons why most faults will not be PLC hardware or software & are much more likely to be due to field device failures or wiring problems
• Define the symptoms & consider possible causes
• Perform appropriate checks to localise the problem
Troubleshooting Mitsubishi FX, Q & A Series hardware problems
• Know the first level checks to begin to quickly distinguish between PLC & field faults
• Know typical fault symptoms for common PLC hardware (module) failures
• Be able to recognise & interpret the meaning of external system diagnostic LEDs
• Be able to correctly interpret the status of I/O LEDs & relate these to the operation of field devices to distinguish between I/O module faults & wiring or field faults
• Know how & where to use a meter to check & confirm I/O module power supplies & for correct operation of digital & analog I/O circuits
• Know quick methods to identify a failed I/O module
• Know the symptoms of using a faulty comms cable
Mitsubishi PLC system Resets & Re-starts
• Understand the effect on the operation of the PLC (program & memory) of stopping & re-starting (Stop-Run) or cycling power
• Understand the implications of Retentive/Non-Retentive memory
• Understand how & when to use “Clear PLC memory”, Resets & Latch Clears & understand the effect of these on system operation
Troubleshooting “simple problems” through interpreting Mitsubishi program code
• Review the different display modes that are available
• Know how to use the Search & Cross Reference tools in a program to trace I/O status
• Know the conditions under which on-screen status is displayed incorrectly
Diagnostic tools in GX Developer
• Know how to generate on-screen Cross Reference data
• Know how to Compare a program in the PLC with a program on disk & be able to interpret the report
• Know how to set up & use the Device/Batch Monitors to monitor multiple I/O points & data registers
• Know how to use the Device Test with Mitsubishi to set/reset a point or to step-on a sequence & understand the dangers
• Know how to use the PLC Diagnostic facility & how to interpret the information
Tips & Tricks when Troubleshooting with Mitsubishi
• Know the easy methods to be able to move around larger programs more effectively
• Simple program tools to time or count events, to prove status & trap intermittent faults
Further Mitsubishi troubleshooting practicals
• Troubleshooting “more complex” problems
• Troubleshooting data handling problems
• Troubleshooting problems with analogs
• Troubleshooting problems which include Indirect Addressing
• Introduction to higher level diagnostic tools e.g. PLC Analyser pro 5
Highly Recommended Follow-up Courses
- Mitsubishi HMIs & Networked Systems
The benefit of attending this further 3 day course is that delegates will be able to gain knowledge & practical experience of maintaining & troubleshooting Mitsubishi PLC automation control systems that use Profibus DP, Ethernet, CC-Link & ASi & Use of E terminal HMIs
- Understanding Mitsubishi Programs
The benefit of attending this further 3 day course is that delegates will be able to gain knowledge & practical experience of modifying or develop routines & applications for Mitsubishi PLC controlled automation control systems