Fuji PLC Manual PDF

The Fuji PLC (Programmable Logic Controller) is an industrial automation control system designed for manufacturing and process control applications. This comprehensive manual covers the FLEX-PC-N series PLCs with features including ladder logic programming, digital/analog I/O modules, communication protocols (RS-232, RS-485, Ethernet), motion control capabilities, and integrated safety functions. Below are key sections for installation, programming, operation, maintenance, and troubleshooting.

Product Overview

Key components: CPU module, power supply unit, digital I/O modules, analog I/O modules, communication modules, programming cable, and configuration software.

Component	Description
CPU Module	Main processing unit with built-in memory and communication ports
Power Supply Unit	24V DC or 100-240V AC input for system power
Digital I/O Modules	16/32 point input/output modules for discrete signals
Analog I/O Modules	4/8 channel modules for analog signal processing
Communication Modules	Ethernet, RS-232/485 for network connectivity
Programming Cable	USB to serial converter for programming connection
Configuration Software	FLEX-PC-N Studio for ladder logic programming
Memory Card Slot	For program backup and data storage
Status Indicators	RUN, ERROR, COMM LEDs for system monitoring
Battery Backup	For program retention during power loss

Installation Guidelines

Unpack and inspect all components. Mount on DIN rail in control cabinet.

1. Mounting: Secure DIN rail; attach modules from left to right (CPU first).
2. Power Connection: Connect power supply to CPU and I/O modules.
3. Wiring: Connect field devices to appropriate I/O terminals.
4. Grounding: Ensure proper grounding for electrical safety.
5. Communication: Connect programming cable and network cables.

WARNING! Disconnect power before installation. Follow local electrical codes and safety regulations.

Hardware Configuration

Configure system parameters using FLEX-PC-N Studio software.

1. System Setup: Define CPU type, memory allocation, and scan time.
2. I/O Assignment: Map physical I/O points to memory addresses.
3. Communication Setup: Configure network parameters and protocols.
4. Safety Settings: Enable safety functions and emergency stop circuits.
5. Save Configuration: Download configuration to PLC memory.

CAUTION! Verify all settings before applying power to prevent equipment damage.

Technical Specifications

• CPU Type: 32-bit RISC processor with floating point unit
• Program Memory: 64KB to 512KB (depending on model)
• Data Memory: 16KB to 128KB RAM with battery backup
• Scan Time: 0.1ms to 10ms (program dependent)
• I/O Capacity: Up to 512 digital points, 64 analog channels
• Communication: Ethernet, RS-232, RS-485, MODBUS RTU/TCP
• Programming Language: Ladder Logic (LD), Function Block Diagram (FBD)
• Power Supply: 24V DC ±10% or 100-240V AC 50/60Hz
• Operating Temperature: 0°C to 55°C (32°F to 131°F)
• Protection Class: IP20 for indoor use

Programming Basics

Use FLEX-PC-N Studio software for ladder logic programming.

Basic Instructions: Contacts, coils, timers, counters, comparators, math functions, data moves.

Program Structure: Main routine, subroutines, interrupt routines. Data Types: BOOL, INT, DINT, REAL, STRING. Programming Tips: Use comments, organize routines logically, test in simulation mode before deployment.

Communication Setup

Configure network connections for SCADA, HMI, and other devices.

1. Ethernet Setup: Set IP address, subnet mask, gateway.
2. Serial Communication: Configure baud rate, parity, stop bits.
3. Protocol Selection: MODBUS TCP/RTU, PROFINET, EtherNet/IP.
4. Device Mapping: Define data exchange with remote devices.
5. Network Diagnostics: Monitor communication status and errors.

Tip: Use ping command to verify network connectivity before configuration.

I/O Module Configuration

Digital and analog I/O module setup and calibration.

1. Module Recognition: System automatically detects installed modules.
2. Address Assignment: Assign I/O addresses in configuration software.
3. Digital I/O: Configure input filters and output response times.
4. Analog I/O: Set scaling, filtering, and alarm limits.
5. Calibration: Perform analog input calibration for accuracy.
6. Diagnostics: Enable module diagnostics for fault detection.

WARNING! Ensure proper signal isolation for analog inputs to prevent noise interference.

Safety Functions

Integrated safety features for machine protection and operator safety.

Emergency Stop: Hardware and software emergency stop circuits. Safety Relays: Configurable safety relay outputs. Access Protection: Password protection for program and configuration changes. Fault Monitoring: Continuous monitoring of system status and safety circuits.

Maintenance Procedures

Regular maintenance ensures optimal performance and longevity.

Monthly: Check terminal connections, clean ventilation, verify backup battery. Quarterly: Test emergency stop circuits, verify I/O operation. Annually: Complete system inspection, firmware updates, battery replacement.

CAUTION! Always disconnect power before performing maintenance. Use proper lockout/tagout procedures.

Compliance Information

CE Certified: Complies with European EMC and Low Voltage Directives. UL Listed: Meets UL 508 industrial control equipment standards. RoHS Compliant: Free of hazardous substances per Directive 2011/65/EU. Copyright © 2025 Fuji Electric Co., Ltd. All rights reserved. For technical support, visit www.fujielectric.com or contact +81-3-5435-7200.

Troubleshooting Guide

Symptom	Possible Cause	Corrective Action
PLC not powering on	Power supply issue	Check voltage input; verify power connections; replace fuse if blown.
Communication failure	Cable/configuration	Verify cable connections; check communication settings; test with known good cable.
I/O points not responding	Wiring/addressing	Check field wiring; verify I/O addressing; test with voltmeter.
Program not running	Mode selection	Ensure PLC is in RUN mode; check for programming errors; verify memory backup.
Analog values inaccurate	Calibration/signal noise	Recalibrate analog inputs; check for electrical noise; verify signal conditioning.

Reset Procedure: Power cycle PLC; use hardware reset if available.

Technical Support: +81-3-5435-7200; www.fujielectric.com/support