Mitsubishi QCPU, Q Mode, QnACPU Programming Manual

• SAFETY PRECAUTIONS •

(You must read these cautions before using the product)

As for the use of the product, please carefully read this manual and the related manuals introduced later. Also, please pay attention to safety adequately and manage the product correctly. The safety cautions shown in this manual apply to the product only. In this manual, the safety precautions are ranked as "DANGER" and "CAUTION".

DANGER

CAUTION

Note that the !CAUTION level may lead to a serious consequence according to the circumstances. Always follow the instructions of both levels because they are important to personal safety.

Please store this manual in order to read whenever it is necessary. Also, always forward this manual to the end users.

Indicates that incorrect handling may cause hazardous conditions, resulting in death or severe injury.

Indicates that incorrect handling may cause hazardous conditions, resulting in medium or slight personal injury or physical damage.

[Design Precautions]

DANGER

• Install a safety circuit external to the programmable controller that keeps the entire system safe

even when there are problems with the external power supply or the programmable controller. Otherwise, it may cause an output error or an operating error, resulting in an accident. (1) Configure a circuit such as an emergency stop circuit and a protective circuit on the outside

of the programmable logic controller.

(2) When the programmable controller detects the following problems, it will stop calculation

and turn off all outputs.

• An overcurrent protective device or an overvoltage protective device in a power supply module start running.

• A watchdog timer error or others is detected with self-checking function in the programmable controller CPU.

All outputs may be turned on, when an error occurs in the part of I/O controlling or others

that the programmable controller CPU cannot detect. Build a fail safe circuit exterior to the programmable controller to keep the entire system safe. As for the fail safe circuit, refer to a CPU module User’s Manual.

• Configure a circuit that turns on an external power supply when the main power of

programmable controller is turned on. If the external power supply is turned on first, it could result in an output error or an operating error.

A - 1

[Design Precautions]

DANGER

• When connecting a peripheral device to the CPU module or connecting a personal computer or

others to an intelligent function module, always configure an interlock circuit in the sequence program to ensure that the whole system always operate safely. Also, make sure to read this manual carefully and check all operations for safety first before executing other control (program changes, changes of operation status (and status control)) of the operating sequence. Especially for the control described above on the remote sequence from an external device, an immediate action may not be taken for a programmable controller’s trouble due to a data communication fault. Configure the interlock circuit in the sequence program. Simultaneously a recovery method for system, in which a data communications fault occurs, should be determined between the external device and the programmable controller CPU.

[Startup/Maintenance Precaution]

CAUTION

• Make sure to read this manual carefully and check all operations for safety first before

connecting a peripheral device to an operating CPU module online (particularly program changes, forced outputs, and changes of operation status). Otherwise, an operating error may cause damage or problems with the modules.

A - 2

REVISIONS

* The manual number is given on the bottom left of the back cover.

Print Date * Manual Number Revision

Dec., 1999 SH (NA) 080040-A First edition

Jun., 2001 SH (NA) 080040-B

Partial addition About Manuals, Chapter 1, Chapter 2, Section 2.1, 3.1, 3.2, 3.3, 3.3.1,

4.2.3, 4.3.2, 4.3.5, Chapter 5, Section 5.1, 5.2, Chapter 6, Chapter 7, Section 8.1, 8.2

Apr., 2002 SH (NA) 080040-C

Correction Chapter 1, Chapter 7, Section 8.1, 8.2, 8.3, 8.4, 8.5

Jan., 2003 SH (NA) 080040-D • Addition of use of Basic model QCPU

• Addition of explanation of incomplete derivative

Overall reexamination

Mar., 2003 SH (NA) 080040-E • Addition of explanation of incomplete derivative to High Performance

model QCPU

Dec., 2003 SH (NA) 080040-F

Jun., 2004 SH (NA) 080040-G

Sep., 2006 SH (NA) 080040-H

Apr.,2007 SH (NA) 080040-I

Mar.,2008 SH (NA) 080040-J

Correction Chapter 1

Addition of Redundant CPU

Partial addition About Manuals, Chapter 1, Chapter 2, Section 2.1, 3.1.1, 3.1.3, 3.2.1,

3.2.3, 4.3.5, 5.1, 5.2, Chapter 6, Chapter 7, Section 8.1.1 to 8.1.4, Section 9.1.1 to 9.1.5, 9.2, Appendix 1

Partial addition

Section 4.2.5, Appendix 2

Addition of Universal model QCPU

Addition module

Q02UCPU, Q03UDCPU, Q04UDHCPU, Q06UDHCPU

Partial correction GENERIC TERMS AND ABBREVIATIONS USED IN THIS MANUAL, Chapter 1, Chapter 2, Section 2.1, 3.1.1, 3.1.3, 3.2.1, 3.2.3, 5.1, Chapter 6, Chapter 7, 8.1.1 to 8.1.5, 9.1.1 to 9.1.5, Appendix 1

Addition of Universal model QCPU

Addition module

Q13UDHCPU, Q26UDHCPU

Partial correction

GENERIC TERMS AND ABBREVIATIONS USED IN THIS MANUAL, Section 2.1, Appendix 1

A - 3

* The manual number is given on the bottom left of the back cover.

Print Date * Manual Number Revision May,2008 SH (NA) 080040-K

Revision due to the addition of Process CPU and Universal model QCPU

Addition module

Q03UDECPU, Q04UDEHCPU, Q06UDEHCPU, Q13UDEHCPU, Q26UDEHCPU

Q02PHCPU, Q06PHCPU

Partial correction

GENERIC TERMS AND ABBREVIATIONS USED IN THIS MANUAL,

Section 2.1, Appendix 1

Japanese Manual Version SH-080022-K

This manual confers no industrial property rights or any rights of any other kind, nor does it confer any patent licenses. Mitsubishi Electric Corporation cannot be held responsible for any problems involving industrial property rights which may occur as a result of using the contents noted in this manual.

A - 4

INTRODUCTION

Thank you for choosing the Mitsubishi MELSEC-Q/QnA Series of Programmable Logic Controllers. Please read this manual carefully so that the equipment is used to its optimum. A copy of this manual should be forwarded to the end User.

SAFETY CAUTIONS ......................................................................................................................................A- 1

REVISIONS .....................................................................................................................................................A- 3

CONTENTS.....................................................................................................................................................A- 5

About Manuals ................................................................................................................................................A- 8

Generic Terms and Abbreviations Used in This Manual ..............................................................................A-11

1. GENERAL DESCRIPTION 1 – 1 to 1 - 3

1.1 PID Processing Method ........................................................................................................................... 1 - 3

2. SYSTEM CONFIGURATION FOR PID CONTROL 2 - 1 to 2 - 2

2.1 Applicable PLC CPU ................................................................................................................................ 2 - 2

3. PID CONTROL SPECIFICATIONS 3 - 1 to 3 - 14

3.1 PID Control by Incomplete derivative ...................................................................................................... 3 - 1

3.1.1 Performance specifications............................................................................................................... 3 - 1

3.1.2 PID operation block diagram and operation expressions ................................................................ 3 - 2

3.1.3 PID control instruction list.................................................................................................................. 3 - 3

3.2 PID Control by Complete Derivative........................................................................................................ 3 - 8

3.2.1 Performance specifications............................................................................................................... 3 - 8

3.2.2 PID operation block diagram and operation expressions ................................................................ 3 - 9

3.2.3 PID control instruction list................................................................................................................ 3 - 10

4. FUNCTIONS OF PID CONTROL 4 - 1 to 4 - 14

4.1 Outline of PID Control .............................................................................................................................. 4 - 1

4.2 Functions of PID Control.......................................................................................................................... 4 - 2

4.2.1 Operation method.............................................................................................................................. 4 - 2

4.2.2 Forward operation and reverse operation ........................................................................................ 4 - 2

4.2.3 Proportionate operation (P operation) .............................................................................................. 4 - 4

4.2.4 Integrating operation (I operation) .................................................................................................... 4 - 5

4.2.5 Differentiating operation (D operation) ............................................................................................. 4 - 6

4.2.6 PID operation..................................................................................................................................... 4 - 8

4.3 Other Functions........................................................................................................................................ 4 - 9

4.3.1 Bumpless changeover function ........................................................................................................ 4 - 9

4.3.2 MV higher/lower limit control function ............................................................................................. 4 - 10

4.3.3 Monitorning PID control with the AD57(S1) (QnACPU only)......................................................... 4 - 11

4.3.4 Function for transfer to the SV storage device for the PV in manual mode .................................. 4 - 12

4.3.5 Changing the PID control data or input/output data setting range (QCPU only) ......................... 4 – 13

A - 5

5. PID CONTROL PROCEDURE 5 - 1 to 5 - 24

5.1 PID Control Data ...................................................................................................................................... 5 - 4

5.1.1 Number of loops to be used and the number of loops to be executed in a single scan ............... 5 - 15

5.1.2 Sampling cycle ................................................................................................................................5 - 16

5.2 I/O Data .................................................................................................................................................. 5 - 18

6. PID CONTROL INSTRUCTIONS 6 - 1 to 6 - 2

7. HOW TO READ EXPLANATIONS FOR INSTRUCTIONS 7 - 1 to 7 - 2

8. INCOMPLETE DERIVATIVE PID CONTROL INSTRUCTIONS AND PROGRAM EXAMPLES 8 - 1 to 8 - 16

8.1 PID Control Instructions ........................................................................................................................... 8 - 1

8.1.1 PID control data settings S.PIDINIT,SP.PIDINIT .......................................... 8 - 2

8.1.2 PID operation S.PIDCONT,SP.PIDCONT................................... 8 - 3

8.1.3 Operation stop/start of designated loop no. S.PIDSTOP,SP.PIDSTOP,S.PIDRUN,SP.PIDRUN

.................................................................................................................................................................... 8 - 5

8.1.4 Parameter change at designated loop S.PIDPRMW,SP.PIDPRMW ................................8 - 6

8.2 PID Control Program Examples .............................................................................................................. 8 - 8

8.2.1 System configuration for program examples.................................................................................... 8 - 8

8.2.2 Program example for automatic mode PID control.......................................................................... 8 - 9

8.2.3 Program example for changing the PID control mode between automatic and manual .............. 8 - 13

9. COMPLETE DERIVATIVE PID CONTROL INSTRUCTIONS AND PROGRAM EXAMPLES 9 - 1 to 9 - 28

9.1 PID Control Instructions ........................................................................................................................... 9 - 1

9.1.1 PID control data settings PIDINIT,PIDINITP................................................. 9 - 2

9.1.2 PID control PIDCONT,PIDCONTP.......................................... 9 - 3

9.1.3 Monitoring PID control status (QnACPU only) PID57,PID57P....................................................... 9 - 5

9.1.4 Operation stop/start of designated loop no. PIDSTOP,PIDSTOPP,PIDRUN,PIDRUNP ......... 9 - 8

9.1.5 Parameter change at designated loop PIDPRMW,PIDPRMWP ....................................... 9 - 9

9.2 PID Control Program Examples (QCPU only) ...................................................................................... 9 - 11

9.2.1 System configuration for program examples.................................................................................. 9 - 11

9.2.2 Program example for automatic mode PID control........................................................................ 9 - 12

9.2.3 Program example for changing the PID control mode between automatic and manual .............. 9 - 15

9.3 PID Control Program Examples (QnACPU only).................................................................................. 9 - 19

9.3.1 System configuration for program examples.................................................................................. 9 - 19

9.3.2 Program example for automatic mode PID control........................................................................ 9 - 20

9.3.3 Program example for changing the PID control mode between automatic and manual ............. 9 – 24

A - 6

APPENDIX APP - 1 to APP - 3

Appendix 1 Processing Time List .............................................................................................................APP - 1

Appendix 2 Anti-Reset Windup Measure .................................................................................................APP - 3

A - 7

About Manuals

Related Manuals

The following manuals are also related to this product. In necessary, order them by quoting the details in the tables below.

Manual Name

Manual Number

(Model Code)

QCPU User's Manual (Function Explanation, Program Fundamentals)

Describes the functions, programming procedures, devices, etc. necessary to create programs.

(Sold separately)

QnACPU Programming Manual (Fundamentals)

Describes how to create programs, the names of devices, parameters, and types of program.

(Sold separately)

QCPU (Q mode) /QnACPU Programming Manual (Common Instructions)

Describes how to use sequence instructions, basic instructions, and application instructions.

(Sold separately)

QnACPU Programming Manual (Special Function)

Describes the dedicated instructions for special function modules available when using the

Q2ACPU(S1), Q3ACPU, and Q4ACPU. (Sold separately)

QnACPU Programming Manual (AD57 Instructions)

Describes the dedicated instructions for controlling an AD57(S1) type CRT controller module available

when using the Q2ACPU(S1), Q3ACPU, or Q4ACPU. (Sold separately)

SH-080484ENG

(13JR73)

IB-66614

(13JF46)

SH-080039

(13JF58)

SH-4013

(13JF56)

IB-66617

(13JF49)

A - 8

Before reading this manual, refer to the user's manual of the used CPU module or the QnACPU Programming Manual (Fundamentals), and confirm which programs, I/O processing, and devices can be used with the used CPU module.

(1) When QCPU is used

QCPU (Q mode)/ QnACPU Programming Manual (Common Instructions)

Describes the instructions other than those given on the ri

ht.

This manual

QCPU (Q mode)/ QnACPU Programming Manual (PID Control Instructions)

Describes the instructions used for PID control.

QCPU User's Manual (Function Explanation, Program Fundamentals)

QCPU (Q mode)/ QnACPU Programming Manual (SFC)

Describes SFC.

Describes the functions, executable programs, I/O processing and device names of the QCPU.

QCPU (Q mode) Programming Manual (MELSAP-L)

Describes MELSAP-L.

QCPU (Q mode) Programming Manual (Structured Text)

Describes the structured text.

A - 9

(2) When QnACPU is used

QCPU (Q mode)/ QnACPU Programming Manual (Common Instructions)

Describes the instructions other than those given on the right.

QnACPU Programming Manual (Special Function Modules)

Describes the instructions for the special function modules such as the AJ71QC24 and AJ71PT32-S3.

QnACPU Programming Manual (Fundamentals)

QnACPU Programming Manual (AD57 Commands)

Describes the AD57 commands for controlling the AD57/AD58.

Describes the programs, I/O processing, device names, etc. that can be executed by the QnACPU.

This manual

QCPU (Q mode)/ QnACPU Programming Manual (PID Control Instructions)

Describes the instructions used for PID control.

QCPU (Q mode)/ QnACPU Programming Manual (SFC)

Describes SFC.

Q4ARCPU only

Q4ARCPU Programming Manual (Application PID Instructions)

Describes the instructions used for applied PID control.

A - 10

Generic Terms and Abbreviations Used in This Manual

This manual uses the following generic terms and abbreviations unless otherwise described.

Generic term/abbreviation Description of generic term/abbreviation

CPU module

QnACPU

QnA

Q4AR Abbreviation of Q4ARCPU

QCPU

QnCPU Abbreviation of Q02CPU

QnHCPU Abbreviation of Q02HCPU, Q06HCPU, Q12HCPU, Q25HCPU

QnPHCPU Abbreviation of Q02PHCPU, Q06PHCPU, Q12PHCPU, Q25PHCPU

QnPRHCPU Abbreviation of Q12PRHCPU, Q25PRHCPU

QnUD(H)CPU

Basic model QCPU

Basic

High Performance model QCPU

High Performance

Process CPU Generic term of Q02PHCPU, Q06PHCPU, Q12PHCPU, Q25PHCPU

Redundant CPU Generic term of Q12PRHCPU, Q25PRHCPU

Universal model QCPU

Universal

Generic term of Basic model QCPU, High Performance model QCPU,

Redundant CPU, Universal model QCPU, QnACPU

Abbreviation of Q2ASCPU, Q2ASCPU-S1, Q2ASHCPU, Q2ASHCPU-S1,

Q2ACPU, Q2ACPU-S1, Q3ACPU, Q4ACPU, Q4ARCPU

Abbreviation of Q2ASCPU, Q2ASCPU-S1, Q2ASHCPU, Q2ASHCPU-S1,

Q2ACPU, Q2ACPU-S1, Q3ACPU, Q4ACPU

Abbreviation of Q00CPU, Q01CPU, Q02CPU, Q02HCPU, Q06HCPU,

Q12HCPU, Q25HCPU, Q12PRHCPU, Q25PRHCPU, Q02UCPU,

Q03UDCPU, Q04UDHCPU, Q06UDHCPU, Q13UDHCPU, Q26UDHCPU,

Q03UDECPU, Q04UDEHCPU, Q06UDEHCPU, Q13UDEHCPU,

Q26UDEHCPU

Abbreviation of Q03UDCPU, Q04UDHCPU, Q06UDHCPU,

Q13UDHCPU, Q26UDHCPU, Q03UDECPU, Q04UDEHCPU,

Q06UDEHCPU, Q13UDEHCPU, Q26UDEHCPU

Generic term of Q00JCPU, Q00CPU, Q01CPU

Generic term of Q02CPU, Q02HCPU, Q06HCPU, Q12HCPU, Q25HCPU

Generic term of Q02UCPU, Q03UDCPU, Q04UDHCPU, Q06UDHCPU,

Q13UDHCPU, Q26UDHCPU, Q03UDECPU, Q04UDEHCPU,

Q06UDEHCPU, Q13UDEHCPU, Q26UDEHCPU

A - 11

MEMO

A - 12

1. GENERAL DESCRIPTION

MELSEC-Q/Qn

1. GENERAL DESCRIPTION

This manual describes the sequence program instructions used to implement PID control with any of the following CPU modules.

• Basic model QCPU (first five digits of serial No. are 04122 or later)

• High Performance model QCPU

• Redundant CPU

• Universal model QCPU

• QnACPU

The Basic model QCPU, High Performance model QCPU, Redundant CPU, and Universal model QCPU have the instructions used to perform PID control by incomplete derivative (PID control instructions) and the instructions used to perform PID control by complete derivative (PID control instructions) as standard features.

The QnACPU has the instructions used to perform PID control by complete derivative (PID control instructions) as standard features.

Since the incomplete derivative PID control instructions and complete derivative PID control instructions are independent of each other, they can be executed at the same time.

The following table indicates the CPU modules that can use the incomplete derivative PID control instructions and complete derivative PID control instructions.

CPU Module Model Name

First five digits of serial No. are

Basic model QCPU

High Performance model QCPU

Redundant CPU Universal model QCPU QnACPU

"04121" or earlier First five digits of serial No. are "04122" or later First five digits of serial No. are "05031" or earlier First five digits of serial No. are "05032" or later

*1: Version 7 or earlier version of GX Developer issues an “instruction code alarm” if it

loads a new CPU instruction realized with GX Developer Version 8.

Incomplete

Derivative

: Usable, : Unusable

Complete Derivative

1 - 1

1. GENERAL DESCRIPTION

MELSEC-Q/Qn

There are the following PID control instructions.

Classification Incomplete Derivative Complete Derivative PID control data setting PID operation PID control status monitor Specified loop No. operation stop Specified loop No. operation start Specified loop No. parameter change

S(P).PIDINIT PIDINIT(P)

S(P).PIDCONT PIDCONT(P)

PID57(P)

S(P).PIDSTOP PIDSTOP(P)

S(P).PIDRUN PIDRUN(P)

S(P).PIDPRMW PIDPRMW(P)

PID control via PID control instructions is implemented by combining the CPU module with the A/D converter module and D/A converter module. In the case of the QnACPU, the PID control status can be monitored using the AD57(S1) CRT controller module.

POINT

(1) The Process CPU is not compatible with the PID control instructions described

in this manual. To implement PID control using the Process CPU, use the process control instructions described in the QnPHCPU/QnPRHCPU Programming Manual (Process Control Instructions).

(2) The Redundant CPU can use the PID control instructions and process control

instructions.

1 - 2

1. GENERAL DESCRIPTION

1.1 PID Processing Method

This section describes the processing method for PID control using PID control

Set value

instructions. (For details on PID operations, see Chapter 4.)

Execute PID control with PID control instructions by loading an A/D converter module and a D/A converter module, as shown in Figure 1.1.

CPU module

PID control instructions

PID operation

Automatic MV

Manual MV

Manual/automatic changeover

D/A conversion module

A/D conversion module

MELSEC-Q/Qn

Controlled system

Sensor

Sequence program

SV: Set Value PV: Process Value MV: Manipulated Value

Figure 1.1 Overview of PID Control Processing

In the PID control processing method, as shown in Figure 1.1, the PID operation is executed using the set value (SV) and the process value (PV) read from the A/D converter module, and the manipulated value (MV) is then calculated. The calculated MV (manipulated value) is output to the D/A converter module.

When a PID operation instruction* is executed in a sequence program, the sampling cycle is measured and a PID operation is performed. PID operation in accordance with the PID operation instruction is executed in preset sampling cycles.