Fuji PLC Programming Manual

The Fuji PLC Programming Manual provides comprehensive guidance for programming Fuji programmable logic controllers, covering hardware configuration, programming languages (ladder logic, function block diagram, structured text), communication setup, troubleshooting, and maintenance procedures. Below are key sections for system overview, programming basics, advanced functions, installation, and technical specifications.

1. System Overview 2. Hardware Configuration 3. Programming Environment Setup 4. Technical Specifications 5. Programming Languages 6. Communication Protocols 7. Advanced Functions 8. Debugging and Monitoring 10. Maintenance & Updates 11. Regulatory Compliance 12. Troubleshooting Guide

System Overview

Key components: CPU module, I/O modules, communication modules, programming software, and peripheral devices.

Component	Description
CPU Module	Central processing unit with memory and processing capabilities
Digital I/O Modules	Input/output modules for digital signals
Analog I/O Modules	Input/output modules for analog signals
Communication Modules	Ethernet, serial, and fieldbus communication interfaces
Power Supply Module	Provides power to the PLC system
Programming Cable	USB/RS232 cable for connecting to programming device
Memory Card	For program storage and backup
Expansion Units	Additional I/O and function modules
Programming Software	Fuji PLC programming suite
HMI Interface	Human-machine interface connectivity

Hardware Configuration

Unpack and inspect all components. Mount on DIN rail or panel.

Install CPU module: Mount on DIN rail, secure with end clamp.
Add I/O modules: Slide modules next to CPU, ensuring proper alignment.
Connect power supply: Verify voltage requirements (24V DC typical).
Wire field devices: Connect sensors, actuators to appropriate I/O terminals.
Install communication modules: Add Ethernet or serial modules as needed.

WARNING! Ensure power is disconnected during installation. Follow proper grounding procedures.

Programming Environment Setup

Install programming software and connect to PLC.

Install software: Run setup program, follow installation wizard.
Connect to PLC: Use programming cable, configure communication parameters.
Create new project: Select PLC model, configure hardware layout.
Set communication: Configure IP address or serial parameters.
Download program: Transfer program to PLC memory.

CAUTION! Backup existing program before downloading new one.

Technical Specifications

Processor: 32-bit RISC processor
Memory: 64KB program memory, 16KB data memory
I/O Capacity: Up to 512 digital I/O points
Scan Time: 0.1ms per 1K instructions typical
Programming Languages: Ladder Logic, Function Block Diagram, Structured Text
Communication: Ethernet, RS232, RS485, Modbus RTU/TCP
Power Supply: 24V DC ±10%
Operating Temperature: 0°C to 55°C
Protection Class: IP20
Certifications: CE, UL, cUL

Programming Languages

Access programming environment via software interface. Multiple language support.

Ladder Logic: Traditional relay-based programming with contacts, coils, timers, counters.

Function Block Diagram: Graphical programming with pre-defined function blocks.

Structured Text: High-level text-based programming language.

Basic Instructions: LD, AND, OR, OUT, TIM, CNT, MOV, CMP. Advanced Functions: PID control, data handling, mathematical operations, communication functions.

Communication Protocols

Ethernet: TCP/IP, Modbus TCP. Serial: RS232/485, Modbus RTU.

Configure network settings: Set IP address, subnet mask, gateway.
Set up protocol: Select Modbus TCP, Ethernet/IP, or proprietary protocol.
Configure device addressing: Set slave addresses for network devices.
Test communication: Verify data exchange with connected devices.

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

Advanced Functions

Supports PID control, data logging, recipe management, and motion control.

PID Control: Configure process loops for temperature, pressure, flow control.
Data Logging: Set up data collection and storage to memory card.
Recipe Management: Create and manage multiple production recipes.
Motion Control: Program positioning and speed control for motors.
Alarm Management: Configure alarm conditions and responses.
Interrupt Handling: Set up interrupt routines for critical events.
Floating Point Math: Perform complex mathematical calculations.
String Operations: Handle text data and messaging.

WARNING! Test advanced functions in simulation mode before deployment.

Debugging and Monitoring

Online monitoring: Real-time view of program execution and variable values. Force I/O: Temporarily override input/output states. Breakpoints: Pause program execution at specific points. Trend monitoring: Graph variable values over time.

Maintenance & Updates

Regular maintenance: Check connections, clean components, verify firmware versions.

CAUTION! Backup program before firmware updates. Follow proper shutdown procedures.

Regulatory Compliance

CE Marking: Complies with European EMC and Low Voltage Directives. UL Certification: Meets UL 508 industrial control equipment standards. RoHS Compliance: Free of restricted hazardous substances. 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, fuses, wiring connections
Communication failure	Cable/configuration	Verify cable connection, check communication settings
Program not running	Mode selection	Ensure PLC is in RUN mode, check for fatal errors
I/O not responding	Wiring/addressing	Check field wiring, verify I/O addressing
Memory error	Memory corruption	Clear memory, reload program from backup

Reset Procedure: Use hardware reset switch or software reset command.

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